CN115911728A - Large-area cooling cage type structure high-grouping-rate battery system, grouping method and vehicle - Google Patents
Large-area cooling cage type structure high-grouping-rate battery system, grouping method and vehicle Download PDFInfo
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- CN115911728A CN115911728A CN202211549598.0A CN202211549598A CN115911728A CN 115911728 A CN115911728 A CN 115911728A CN 202211549598 A CN202211549598 A CN 202211549598A CN 115911728 A CN115911728 A CN 115911728A
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Abstract
The invention relates to the technical field of new energy automobiles, and discloses a large-area cooling cage type structure high-grouping-rate battery system, a grouping method and a vehicle, wherein the large-area cooling cage type structure high-grouping-rate battery system comprises an oversized battery pack unit, a liquid cooling pipe integrated battery lower box body, an integrated sampling connection assembly, a battery management system cluster control unit, an upper box body, an all-in-one system and a structural adhesive; the large-area cooling type high-efficiency heat management system, the ultra-large-size battery pack unit, the liquid cooling pipe integrated battery box body, the direct-connected battery cell sampling connection system, the cage structure protection system, the battery cell expansion safety protection system and the thermal barrier protection system are integrated, the charge multiplying power, the grouping rate and the safety protection performance of the battery system are cooperatively improved through the large-area cooling mode, the CTP integrated grouping and the multifunctional fusion of all parts, the charge multiplying power, the grouping rate and the safety protection performance of the battery system are cooperatively improved, and meanwhile, the platform application, the low cost, the high space utilization rate and the high production efficiency are considered.
Description
Technical Field
The invention relates to the technical field of electric automobiles, in particular to a large-area cooling cage type structure high-grouping-rate battery system, a grouping method and a vehicle.
Background
With the continuous improvement of the permeability of the electric automobile, the problems of low charging efficiency, anxiety mileage, use safety and other user pain points become important factors restricting the development of the industry, and need to be solved urgently; the influence of the power battery as the core assembly of the electric automobile on the performance of the whole automobile and the user experience is more and more remarkable, the cooperative improvement of the charging rate, the grouping rate and the safety protection of a battery system becomes a contradiction focus for solving the problems, the prior art can only solve one or two problems, but the other disadvantage is particularly prominent, for example, the improvement of the charging rate or the improvement of the safety protection is solved, and the grouping rate is greatly reduced.
Disclosure of Invention
In order to solve the problems, the invention provides a large-area cooling cage-type structure high-grouping-rate battery system, which integrates a large-area cooling type efficient thermal management system, an oversized battery Pack unit, a liquid cooling pipe integrated battery box body, a direct-connected battery Cell sampling connection system, a cage-type structure protection system, a battery Cell expansion safety protection system and a thermal barrier protection system.
The invention provides a large-area cooling cage type structure high-grouping-rate battery system which comprises an oversized battery pack unit, a liquid cooling pipe integrated battery lower box body, an integrated sampling connection assembly, a battery management system cluster control unit, an upper box body, an all-in-one system and structural adhesive, wherein the oversized battery pack unit is arranged on the upper box body;
the oversized battery Pack unit and the lower box body of the liquid cooling pipe integrated battery are installed and connected in a structural adhesive bonding mode to form a CTP (Cell to Pack) type bolt-free connection integrated battery Pack structure;
the integrated sampling connection assembly is arranged at the upper part of the oversized battery pack unit, and the integrated sampling connection assembly and the oversized battery pack unit are electrically and mechanically connected in a laser welding mode;
the battery management system cluster control unit is arranged on one side of the oversized battery pack unit, is mechanically fixed with the integrated lower battery box of the liquid cooling pipe in a bolt connection mode, and is electrically connected with the integrated sampling connecting assembly in a sampling and balancing mode in a connector matching, inserting and locking mode;
the upper box body is arranged above the integrated sampling connecting assembly and is mechanically fixed with the liquid cooling pipe integrated battery lower box body in a bolt connection mode;
the all-in-one system is fixed on the upper surface of the upper box body in a bolt connection mode, the all-in-one system is electrically connected with the cluster control unit of the battery management system to achieve data communication, and meanwhile, the all-in-one system is electrically connected with the positive electrode and the negative electrode of the oversized battery pack unit in a bolt connection mode to achieve high-voltage electricity.
The all-in-one system comprises a plurality of relays, a high-voltage main loop fuse, a high-voltage connecting element, a wire harness, a battery management system main control unit, a DC/DC assembly, a vehicle-mounted charger and a high-voltage output connector, wherein the relays, the high-voltage main loop fuse, the battery management system main control unit, the DC/DC assembly, the vehicle-mounted charger and the high-voltage output connector are connected into a whole through the high-voltage connecting element and the wire harness and are fixed on a base of the all-in-one system so as to realize the integral physical integration of high-low voltage connection and mechanical connection and realize the charge and discharge control function of a battery pack;
the ultra-large battery pack unit comprises a plurality of battery packs I, II, III, a middle beam assembly, a connecting water pipe, a heat insulation assembly, an end plate I assembly and an end plate II assembly; the end plate I assembly and the end plate II assembly are respectively arranged at two ends of the oversized battery pack unit, the inner sides of the end plate assemblies at the two ends are respectively provided with a battery pack II and a battery pack III in a close fit manner, a plurality of battery packs I and heat insulation assemblies are sequentially and alternately arranged between the battery packs II and the battery packs III, and a heat insulation assembly is clamped between two adjacent groups of battery packs I; a middle beam assembly is fixedly clamped between two adjacent groups of battery packs in the middle of the plurality of groups of battery packs I; the upper end and the lower end of the liquid cooling plate on the battery pack I, the upper end and the lower end of the liquid cooling plate on the battery pack II and the upper end and the lower end of the liquid cooling plate on the battery pack III are respectively connected with a water pipe in series to form a cage-type liquid cooling circulation passage;
each group of battery pack I comprises two battery core groups and a liquid cooling plate I assembly, wherein the two battery core groups are respectively arranged at two sides of the liquid cooling plate I assembly, so that the one-side large-area cooling of the battery cells is realized, the positive and negative electrodes of the battery cells of the two battery core groups corresponding to the left and right are arranged in the same direction or in the reverse direction, and the positive and negative electrodes of the battery core groups at two sides can be flexibly adjusted to be arranged in the same direction (in parallel) or in the reverse direction (in series) according to the design requirements of the serial and parallel specifications of the battery cells; each electric core group comprises electric cores and heat insulation pads, the heat insulation pads are clamped between every two adjacent electric cores, a blue film is coated outside each electric core to achieve an insulation effect, and a window is formed in the bottom of the blue film of each electric core so that the structural adhesive can be adhered to an aluminum shell of each electric core; each liquid cooling plate I assembly comprises a liquid cooling plate I and two heat conducting elements; the two heat conducting elements are respectively arranged on the left side and the right side of the liquid cooling plate I, each liquid cooling plate I is an aluminum alloy harmonica pipe or a brazing aluminum plate, two ends of each liquid cooling plate I are respectively and fixedly communicated with a three-way pipe I of a battery pack, the horizontal bidirectional water pipe joint end of the three-way pipe I of the battery pack is a universal joint, and the liquid cooling plate I has the functions of heat insulation and cooling and can block heat spreading under the thermal runaway of a battery cell; each heat conducting element is formed by sticking double-sided adhesive tapes on two sides of a heat conducting base material, and the thickness and physical parameters of the heat conducting base material and the double-sided adhesive tapes can be designed and selected according to actual requirements;
the battery pack II comprises two electric core groups and a liquid cooling plate II assembly, wherein the structures of the two electric core groups are the same as those of the battery pack I; the liquid cooling plate II assembly comprises a liquid cooling plate I and two heat conducting elements, the structure of the liquid cooling plate I is the same as that of the liquid cooling plate I assembly, the liquid cooling plate II assembly further comprises two through holes, and two ends of the liquid cooling plate II assembly are respectively fixedly communicated with the two through holes;
the battery pack III comprises two electric core groups and a liquid cooling plate III assembly which have the same structure as the battery pack I, the liquid cooling plate III assembly comprises a liquid cooling plate I and two heat conducting elements which have the same structure as the liquid cooling plate I assembly, the liquid cooling plate III assembly further comprises two battery pack III tee joints, two ends of the liquid cooling plate III assembly are respectively and fixedly communicated with a battery pack III tee joint, the left end of a horizontal bidirectional water pipe connector of the battery pack III tee joint is a universal connector, and the right end of the horizontal bidirectional water pipe connector of the battery pack III tee joint is a connector matched with a water inlet pipe assembly or a water outlet pipe assembly;
the middle beam assembly comprises a middle beam and a buffering assembly I; the buffer assemblies I are arranged on the left side surface and the right side surface of the middle beam; the buffer component I is made of an elastic compressible material, and physical parameters such as a compression rate and the like of the buffer component I can be adjusted according to design requirements; the middle beam is a movable beam, two ends of the middle beam are provided with connecting water pipe avoiding openings so as to be convenient for assembling the connecting water pipes, and the middle beam is made of light aluminum alloy, aluminum profile or cast aluminum;
the heat insulation assembly comprises a heat insulation element and a buffer assembly I, wherein the buffer assembly I is arranged on the left side surface and the right side surface of the heat insulation element; the heat insulation element is a hollow metal sealing cavity, and a high specific heat solution is contained in the metal sealing cavity, so that the heat insulation element has the characteristic of high specific heat capacity, can quickly absorb heat under the condition that a battery core is out of control of heat, and achieves the effects of heat insulation and temperature reduction;
the end plate I assembly comprises an end plate I and a buffer assembly II; the buffer component II is arranged on one side surface of the end plate I; the end plate I is made of a non-metal composite material, and can play a role in insulation and protection and simultaneously has a heat insulation function; the material of the buffer component II is the same as that of the buffer component I; the end plate II assembly comprises an end plate II and a buffer assembly II, the buffer assembly II is arranged on one side surface of the end plate II, and the material of the end plate II is the same as that of the end plate I;
the liquid cooling pipe integrated lower battery box comprises a lower box component, a water inlet pipe component and a water outlet pipe component; the water inlet pipe assembly and the water outlet pipe assembly are embedded and communicated with an internal pipeline of a right longitudinal side beam of the lower box body assembly, so that the structure of the water inlet and outlet pipeline is compact, the space utilization rate of a battery pack is effectively improved, more arrangement space is provided for an electric core, the lower box body of the liquid cooling pipe integrated battery is provided with a glue layer limiting convex edge, the glue layer limiting convex edge is arranged on a bottom plate of the lower box body and is used for controlling the thickness of a glue layer of a mechanism, the effective bonding between the ultra-large-size battery pack and the lower box body of the liquid cooling pipe integrated battery is ensured, the usage amount of structural glue is reduced, and the cost and the weight are reduced;
the integrated sampling connection assembly comprises a sampling execution unit, an inter-cell bus, an upper protection unit and a lower protection unit; the sampling execution unit can be an FPC (Flexible Printed Circuit), a FFC (Flexible Flat Cable) or a wire harness, has the functions of collecting the cell voltage and the temperature and is provided with a signal transmission connector; the inter-cell busbar is made of aluminum or copper and is used for series and parallel electric connection between the cells; the sampling execution unit is connected with the busbar between the battery cores in a welding mode to realize the voltage sampling of the battery cores; the upper protection unit and the lower protection unit are used for integrating the sampling execution unit and the inter-cell busbar into a whole through a hot pressing process or a bonding mode, so that the overall thickness and size are reduced, the Z-direction space occupation ratio of a battery system is reduced, the overall weight and cost are reduced, and the device has the advantages of simple processing process, high dimensional precision, small deformation and the like.
In the oversized battery pack unit, the heat insulation assembly and the middle beam assembly are replaced by the I assemblies of the liquid cooling plates, and each I assembly of the replaced liquid cooling plates is communicated with the water pipe joints of the left and right adjacent liquid cooling plates through the connecting water pipes, so that the double-side large-surface cooling of the battery cell can be realized.
The upper and lower water pipe joints of the adjacent liquid cooling plate I assembly, the upper and lower water pipe joints of the liquid cooling plate II assembly and the upper and lower water pipe joints of the liquid cooling plate III assembly are respectively communicated by a plurality of connecting water pipes to form main pipelines at the upper and lower ends; the water pipe joints on the right sides of the upper end and the lower end of the liquid cooling plate III assembly are respectively in seamless connection with the water pipe joints of the water inlet pipe assembly and the water outlet pipe assembly to form an integrally communicated large-area cooling type heat management system; the coolant flow direction is from the water inlet pipe subassembly inflow battery system, flows into III subassemblies of liquid cold board, I subassemblies of liquid cold board and II subassemblies of liquid cold board respectively through the upper end main line, assembles the lower extreme main line again and flows out battery system by the outlet pipe subassembly.
The two ends of the liquid cooling plate I assembly, the liquid cooling plate II assembly, the heat insulation element and the middle beam of the uniform distribution are respectively bonded and fixed with the upper transverse side beam, the lower transverse side beam and the lower box bottom plate of the lower box assembly through the structural adhesive to form a cage type structure protection system, the high-strength cage type structure improves the rigidity of the whole structure of the battery pack, and the mechanical safety of the battery system is effectively improved. Meanwhile, the liquid cooling plate assembly and the heat insulation element are integrated in functions of mechanical structure protection, heat management, heat insulation and the like, and the battery system grouping rate is further improved.
The liquid cooling plate I assembly, the liquid cooling plate II assembly, the liquid cooling plate III assembly, the middle beam, the heat insulation element and the heat insulation pad form a heat insulation protection system, all the electric cores are separated independently, effective isolation can be guaranteed under the condition that a single electric core triggers thermal runaway, further thermal spreading is prevented, and the thermal runaway protection safety of a battery system is improved; meanwhile, the liquid cooling plate assembly and the middle beam are integrated in functions of mechanical structure protection, heat management, heat insulation and the like, and the grouping rate of the battery system is further improved.
Buffer unit I and buffer unit II constitute electric core inflation safety protection system jointly, buffer unit I set up in thermal-insulated component both sides face, buffer unit I set up in middle part roof beam both sides face, buffer unit II set up in I side of end plate, buffer unit II set up in II side of end plate to realize that a side of every electric core all contacts with buffer unit, provide the circulation inflation space for every electric core, ensured the safety in utilization and the life of electric core.
The integrated sampling connection assembly and the battery management system cluster control unit jointly form the direct-connected battery core sampling connection system; the battery management system cluster control unit is arranged on one side of the ultra-large-size battery pack unit, the integrated sampling connecting assembly is directly connected with the battery management system cluster control unit through the connector, a middle transitional connection wire harness is omitted, the space utilization rate of the battery pack is improved, the number of parts is reduced, the weight is reduced, the sampling connection assembly process is simplified, and the overall cost is reduced.
The invention also provides a grouping method of the large-area cooling cage type structure high-grouping-rate battery system, which comprises the following steps of 5:
s1: sorting and cleaning the battery cells;
s2: the battery core pole is inverted downwards and then stacked into a battery core group, or the battery core pole is inverted and then stacked into a battery pack, and the battery core pole faces downwards;
s3: the electric core assembly is adhered with the liquid cooling plate assembly to form a battery pack;
0S4: stacking an end plate assembly, a battery pack, a heat insulation assembly, a middle beam assembly, a connecting water pipe and the like into an oversized battery pack unit;
s5: after the lower battery box body is coated with structural adhesive, the lower battery box body is turned over at 180 ℃ to enable the opening of the box body to be punched down and reversed to advance, and the assembly of the super-large battery pack unit into the box is realized;
s6: after the whole body is clamped, the whole body is turned over at 180 ℃ and is straightened, and the electric core pole is upward;
5S7: the integrated sampling connection assembly is welded with the oversized battery pack unit;
s8: the battery management system cluster control unit is fixedly arranged on the battery lower box body, and the integrated sampling connection assembly is directly connected with the battery management system cluster control unit in an inserted mode;
s9: installing an upper box body assembly and an all-in-one system;
s10: and detecting the offline of the battery system.
The grouping method 0 realizes the assembly of the oversized battery pack unit and the lower battery box through the technological forms of inverting the oversized battery pack unit and reversely buckling the lower battery box, solves the problems that the oversized battery pack unit is limited by the integral size and is too heavy to be easily hoisted into a box, simplifies the assembly technology, improves the production efficiency and reduces the production cost; the grouping method is also applicable to CTC (Battery Chassis integration)
The assembly of the battery pack with the downward-facing battery cell pole is realized.
5
The present invention also provides a vehicle comprising a large area cooling cage high-battery-rate battery system assembled using the large area cooling cage high-battery-rate battery system grouping method.
Advantageous effects
The large-area cooling type high-efficiency heat management system, the oversized battery pack unit, the liquid cooling pipe integrated battery box body, the direct-connected battery cell sampling connection system, the cage-type structure protection system, the battery cell expansion safety protection system and the thermal barrier protection system are integrated, the charging rate, the grouping rate and the safety protection performance of the battery system are cooperatively improved through a large-area cooling mode, CTP (computer-to-plate) integrated grouping and multifunctional fusion of all parts, the charging rate, the grouping rate and the safety protection performance of the battery system are cooperatively improved, and the platform application, the low cost, the high space utilization rate and the high production efficiency are simultaneously considered.
Drawings
Fig. 1 is a block diagram of a battery system according to the present invention.
Fig. 2 is an exploded view of the battery system of the present invention.
Fig. 3 is a schematic view of the structure of an oversized battery unit according to the invention.
Fig. 4 is an enlarged schematic view of the partial structure of the part I in fig. 3.
Fig. 5 is a schematic view of the structure of a battery pack i according to the present invention.
Fig. 6 isbase:Sub>A schematic sectional view taken along linebase:Sub>A-base:Sub>A of fig. 5.
Fig. 7 is a schematic structural view of the center sill assembly of the present invention.
FIG. 8 is a schematic view of the construction of the insulation assembly of the present invention.
Fig. 9 is a schematic structural diagram of an end plate I assembly and an end plate II assembly of the invention.
Fig. 10 is a schematic diagram of the structure of the integrated liquid cooling tube lower battery box of the invention.
FIG. 11 is a schematic view of a large area cooled thermal management system of the present invention.
Figure 12 is a schematic diagram of the cage structure containment system of the present invention.
Fig. 13 is a schematic view of a partial sectional structure taken along line B-B of fig. 12.
Fig. 14 is a schematic view of an integrated sampling connection assembly of the present invention.
Fig. 15 is a schematic structural diagram of the direct connection type cell sampling connection system of the present invention.
Fig. 16 is a process flow diagram of a battery system grouping method of the present invention.
In the figure:
1. an oversized battery pack unit; 11. a battery pack I; 111. the electric core group; 1111. an electric core; 1112. a heat insulating pad; 112. a liquid cooling plate I component; 1121. a liquid cooling plate I; 1122. a heat conducting element; 12. a battery pack II; 121. a liquid cooling plate II assembly; 13. a battery pack III; 131. a liquid cooled plate III assembly; 14. a middle beam assembly; 141. a middle beam; 142. a buffer component I; 15. connecting a water pipe; 16. an insulating assembly; 161. an insulating element; 17. an end plate I assembly; 171. an end plate I; 172. a buffer component II; 18. an end plate II assembly; 181. an end plate II;
2. the liquid cooling pipe integrated battery lower box body; 21. a lower case assembly; 211. a right longitudinal edge beam; 212. a glue layer limiting convex rib; 213. a lower box body bottom plate; 214. an upper transverse edge beam; 215. a lower transverse edge beam; 22. a water inlet pipe assembly; 23. a water outlet pipe assembly;
3. an integrated sampling connection assembly; 31. a sampling execution unit; 32. a busbar between the electric cores; 33. an upper protection unit; 34. a lower protection unit;
4. a battery management system cluster control unit;
5. an upper box body;
6. an all-in-one system;
7. structural adhesive;
10. a large-area cooled thermal management system;
20. a cage structure protection system;
30. a thermal barrier protection system;
40. a cell expansion safety protection system;
50. direct-connected type electricity core sampling connected system.
Detailed Description
In order to make the technical problems solved, the technical solutions adopted and the technical effects achieved by the present invention clearer, the technical solutions of the present invention are further described below by way of specific embodiments with reference to the accompanying drawings. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some but not all of the elements associated with the present invention are shown in the drawings.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Wherein the terms "first position" and "second position" are two different positions.
In the description of the present invention, it should be noted that unless otherwise explicitly stated or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection or a removable connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1
Referring to fig. 1-2, the large-area cooling cage-type high-grouping-rate battery system includes an oversized battery unit 1, a liquid-cooling-pipe integrated battery lower case 2, an integrated sampling connection assembly 3, a battery management system cluster control unit 4, an upper case 5, an all-in-one system 6 and a structural adhesive 7;
the oversized battery pack unit 1 and the liquid cooling pipe integrated battery lower box body 2 are installed and connected in a bonding mode through structural adhesive 7;
the integrated sampling connection assembly 3 is arranged at the upper part of the oversized battery pack unit 1, and the electrical connection and the mechanical connection between the two are realized in a laser welding mode;
the battery management system cluster control unit 4 is arranged on one side of the oversized battery pack unit 1, the battery management system cluster control unit 4 is mechanically fixed with the liquid cooling pipe integrated battery lower box body 2 in a bolt connection mode, and is electrically connected with the integrated sampling connection assembly 3 in a sampling and balancing mode in a connector matching, inserting and locking mode;
the upper box body 5 is arranged above the integrated sampling connecting assembly 3 and is mechanically fixed with the liquid cooling pipe integrated battery lower box body 2 in a bolt connection mode;
the all-in-one system 6 is fixed on the upper surface of the upper box body 5 in a bolt connection mode, the all-in-one system 6 and the battery management system cluster control unit 4 are electrically connected to achieve data communication, and meanwhile, the all-in-one system 6 and the positive and negative electrodes of the oversized battery pack unit 1 are electrically connected in a high-voltage mode in a bolt connection mode.
The all-in-one system 6 comprises a plurality of relays, a high-voltage main circuit fuse, a high-voltage connecting element, a wire harness, a battery management system main control unit, a DC/DC assembly, a vehicle-mounted charger and a high-voltage output connector, wherein the relays, the high-voltage main circuit fuse, the battery management system main control unit, the DC/DC assembly, the vehicle-mounted charger and the high-voltage output connector are connected into a whole through the high-voltage connecting element and the wire harness respectively and are fixed on a base (not shown in the figure) of the all-in-one system 6.
Referring to fig. 3 to 4, the oversized battery pack unit 1 comprises twenty-two battery packs i 11, ii 12, iii 13, a middle beam assembly 14, a connecting water pipe 15, a heat insulation assembly 16, an end plate i assembly 17 and an end plate ii assembly 18; the end plate I assembly 17 and the end plate II assembly 18 are respectively arranged at two ends of the oversized battery pack unit 1, the inner sides of the end plate assemblies at the two ends are respectively and closely attached with a battery pack II 12 and a battery pack III 13, twenty groups of battery packs I11 and heat insulation assemblies 16 are sequentially and alternately arranged between the battery pack II 12 and the battery pack III 13, and a heat insulation assembly 16 is clamped between the two adjacent groups of battery packs I11; a middle beam assembly 14 is fixedly clamped between two adjacent groups of battery packs in the middle of the twenty-two groups of battery packs I11; the upper and lower ends of the liquid cooling plate on the twenty-two groups of battery packs I11, the upper and lower ends of the liquid cooling plate on the battery pack II 12 and the upper and lower ends of the liquid cooling plate on the battery pack III 13 are respectively connected with a water pipe 15 in series to form a liquid cooling circulation channel of a cage structure.
As shown in fig. 4 to 5, each group of battery pack i 11 includes two electric core groups 111 and a liquid cooling plate i assembly 112, the two electric core groups 111 are respectively disposed at two sides of the liquid cooling plate i assembly 112, and positive and negative poles of electric cores of the two electric core groups 111 corresponding to the left and right are arranged in the same direction or in the opposite direction; each electric core group 111 comprises electric cores 1111 and a heat insulation pad 1112, the heat insulation pad 1112 is clamped between every two adjacent electric cores 1111, a blue film is coated outside each electric core 1111, and a window is formed at the bottom of the blue film of each electric core 1111; referring to fig. 4 and 6, each liquid-cooled plate i assembly 112 includes a liquid-cooled plate i 1121 and two heat-conducting elements 1122; the two heat conduction elements 1122 are respectively arranged on the left side and the right side of the liquid cooling plate I1121, each liquid cooling plate I1121 is an aluminum alloy harmonica tube, two ends of each liquid cooling plate I1121 are respectively and fixedly communicated with a three-way pipe I of a battery pack, and the horizontal bidirectional water pipe joint end of the three-way pipe I of the battery pack is a universal joint; each thermally conductive element 1122 is formed of a thermally conductive substrate with double-sided adhesive on both sides.
Referring to fig. 3 and 6, the battery pack ii 12 includes two battery cell groups having the same structure as the battery pack i 11 and a liquid cooling plate ii assembly 121; this II subassemblies of liquid cooling board 121 includes I1121 and two heat conduction components 1122 of liquid cooling board with I subassembly 112 of liquid cooling board the same structure, and II subassemblies of liquid cooling board 121 still includes two logical, and II subassemblies of liquid cooling board 121 both ends of fixed intercommunication respectively have a two logical.
Referring to fig. 4 and 6, the battery pack iii 13 includes two battery cell groups and a liquid cooling plate iii assembly 131 having the same structure as the battery pack i 11, the liquid cooling plate iii assembly 131 includes a liquid cooling plate i 1121 and two heat conducting elements 1122 having the same structure as the liquid cooling plate i assembly 112, the liquid cooling plate iii assembly 131 further includes two battery pack iii tees, two ends of the liquid cooling plate iii assembly 131 are respectively and fixedly communicated with one battery pack iii tee, the left end of the horizontal bidirectional water pipe connector of the battery pack iii tee is a universal connector, and the right end of the horizontal bidirectional water pipe connector of the battery pack iii tee is a connector matched with the water inlet pipe assembly and the water outlet pipe assembly.
Referring to fig. 7, the middle beam assembly 14 includes a middle beam 141 and a cushion assembly i 142; the buffer assemblies I142 are arranged on the left side surface and the right side surface of the middle beam 141; the buffer component I142 is made of an elastic compressible material; the middle beam 141 is a movable beam, two ends of the middle beam are provided with connecting water pipe avoiding openings, and the middle beam is made of light aluminum alloy.
Referring to fig. 8, the thermal insulation assembly 16 includes a thermal insulation element 161 and a buffer assembly i 142, wherein the buffer assembly i 142 is disposed on left and right sides of the thermal insulation element 161; the insulating element 161 is a hollow metal sealed cavity containing a high specific heat solution.
Referring to fig. 9, the end plate i assembly 17 comprises an end plate i 171 and a buffer assembly ii 172; the buffer component II 172 is arranged on one side surface of the end plate I171; the end plate I171 is made of a non-metal composite material; the material of the buffer component II 172 is the same as that of the buffer component I142; II subassemblies of end plate 18 include II 181 and buffer module II 172 of end plate, buffer module II 172 set up in II 181 a side of end plate, II 181 materials of end plate with I171 of end plate are the same.
Referring to fig. 10, the liquid cooling pipe integrated battery lower case 2 includes a lower case component 21, a water inlet pipe component 22, and a water outlet pipe component 23; the embedded interior pipeline that establishes that communicates in the vertical boundary beam 211 in right side of lower box subassembly 21 of inlet tube subassembly 22 and outlet pipe subassembly 23, box 2 is provided with the spacing bead 212 of glue film under the liquid cooling pipe integrated form battery, and this spacing bead 212 of glue film sets up on lower box bottom plate 213.
Referring to fig. 14, the integrated sampling connection assembly 3 includes a sampling execution unit 31, an inter-cell bus bar 32, an upper protection unit 33, and a lower protection unit 34; the sampling performing unit 31 may be an FPC; the inter-cell bus bar 32 is made of aluminum; the sampling execution unit 31 is connected with the inter-cell bus bar 32 in a welding manner; the sampling execution unit 31 and the inter-cell bus bar 32 are integrated into one body by the upper protection unit 33 and the lower protection unit 34 through a hot press process.
Referring to fig. 1 and 11, a plurality of connecting water pipes 15 respectively communicate the water pipe joints at the upper and lower ends of the adjacent liquid cooling plate i assembly 112, the water pipe joints at the upper and lower ends of the liquid cooling plate ii assembly 121, and the water pipe joints at the upper and lower ends of the liquid cooling plate iii assembly 131 to form main pipelines at the upper and lower ends; the water pipe joints on the right sides of the upper end and the lower end of the liquid cooling plate III assembly 131 are respectively in seamless connection with the water pipe joints of the water inlet pipe assembly 22 and the water outlet pipe assembly 23 to form the integrally communicated large-area cooling type heat management system 10; the cooling liquid flows into the battery system from the water inlet pipe assembly 22, flows into the liquid cooling plate III assembly 131, the liquid cooling plate I assembly 112 and the liquid cooling plate II assembly 121 through the upper end main pipeline respectively, then is converged into the lower end main pipeline and flows out of the battery system through the water outlet pipe assembly 23.
Referring to fig. 1, 12-13, two ends of the uniformly distributed liquid cooling plate i assembly 112, the liquid cooling plate ii assembly 121, the liquid cooling plate iii assembly 131, the heat insulating element 161, and the middle beam 141 are respectively bonded and fixed with the upper transverse edge beam 214, the lower transverse edge beam 215, and the lower box bottom plate 213 of the lower box assembly 21 by the structural adhesive 7, so as to form the cage structure protection system 20.
Referring to fig. 1, 3-8, the liquid-cooled panel i assembly 112, the liquid-cooled panel ii assembly 121, the liquid-cooled panel iii assembly 131, the middle beam 141, the heat insulation element 161, and the heat insulation mat 1112 form a thermal insulation protection system 30, and separate all the cells individually.
Referring to fig. 1, 7-9, the buffer assembly i 142 and the buffer assembly ii 172 together form a cell expansion safety protection system 40, the buffer assembly i 142 is disposed on two sides of the thermal insulation element 161, the buffer assembly i 142 is disposed on two sides of the middle beam 141, the buffer assembly ii 172 is disposed on one side of the end plate i 171, and the buffer assembly ii 172 is disposed on one side of the end plate ii 181.
Referring to fig. 2 and fig. 15, the integrated sampling connection assembly 3 and the battery management system cluster control unit 4 together form a direct connection type cell sampling connection system 50; the battery management system cluster control unit 4 is arranged on one side of the ultra-large-size battery pack unit 1, and the integrated sampling connection assembly 3 is directly connected with the battery management system cluster control unit 4 through a connector.
Example 2
In the oversized battery pack unit 1, the heat insulation assembly 16 and the middle beam assembly 14 are replaced by the liquid-cooling plate I assemblies 112, and each replaced liquid-cooling plate I assembly 112 is communicated with the water pipe joints of the left and right adjacent liquid-cooling plates through the connecting water pipes 15.
Example 3
Referring to fig. 1-16, a method for grouping a large area cooling cage high-grouping rate battery system, comprising the steps of:
s1: sorting and cleaning the battery cells;
s2: the battery core pole is inverted downwards and then stacked to form a battery core group, or the battery core pole is inverted after being stacked to form a battery pack and then the battery pole faces downwards;
s3: the electric core assembly is adhered with the liquid cooling plate assembly to form a battery pack;
s4: stacking an end plate assembly, a battery pack, a heat insulation assembly, a middle beam assembly, a connecting water pipe and the like into an oversized battery pack unit;
s5: after the lower battery box body is coated with structural adhesive, the lower battery box body is turned over at 180 ℃ so that the opening of the lower battery box body is punched down and reversed to advance, and the assembly of the oversized battery pack unit into the box is realized;
s6: after the whole body is clamped, the whole body is turned over at 180 ℃ and is aligned, and the terminal of the battery cell is upward;
s7: the integrated sampling connection assembly is welded with the oversized battery pack unit;
s8: the battery management system cluster control unit is fixedly arranged on the battery lower box body, and the integrated sampling connection assembly is directly connected with the battery management system cluster control unit in an inserted mode;
s9: installing an upper box body assembly and an all-in-one system;
s10: and (5) detecting the offline of the battery system.
Example 4
A vehicle comprising a large area cooling cage high-battery system of example 1 assembled using the method of grouping large area cooling cage high-battery systems of example 2.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. Big face cooling cage structure high block rate battery system, its characterized in that: the system comprises an oversized battery pack unit (1), a liquid cooling pipe integrated battery lower box body (2), an integrated sampling connection assembly (3), a battery management system cluster control unit (4), an upper box body (5), an all-in-one system (6) and structural glue (7);
the ultra-large battery pack unit (1) is connected with the liquid cooling pipe integrated battery lower box body (2) in an installing mode through structural adhesive (7) in a bonding mode;
the integrated sampling connection assembly (3) is arranged at the upper part of the oversized battery pack unit (1), and the integrated sampling connection assembly and the oversized battery pack unit are electrically and mechanically connected in a laser welding mode;
the battery management system cluster control unit (4) is arranged on one side of the oversized battery pack unit (1), the battery management system cluster control unit (4) is mechanically fixed with the liquid cooling pipe integrated battery lower box body (2) in a bolt connection mode, and is in sampling and balanced electrical connection with the integrated sampling connecting assembly (3) in a connector butt-joint insertion locking mode;
the upper box body (5) is arranged above the integrated sampling connecting assembly (3) and is mechanically fixed with the liquid cooling pipe integrated battery lower box body (2) in a bolt connection mode;
the all-in-one system (6) is fixed on the upper surface of the upper box body (5) in a bolt connection mode, the all-in-one system (6) and the battery management system cluster control unit (4) are electrically connected to achieve data communication, and meanwhile the all-in-one system (6) and the positive and negative poles of the oversized battery pack unit (1) are electrically connected in a high-voltage mode.
2. A large area cooling cage high battery system according to claim 1, wherein: the all-in-one system (6) comprises a plurality of relays, a high-voltage main loop fuse, a high-voltage connecting element, a wire harness, a battery management system main control unit, a DC/DC assembly, a vehicle-mounted charger and a high-voltage output connector, wherein the relays, the high-voltage main loop fuse, the battery management system main control unit, the DC/DC assembly, the vehicle-mounted charger and the high-voltage output connector are connected into a whole through the high-voltage connecting element and the wire harness respectively and are fixed on a base of the all-in-one system (6);
the ultra-large battery pack unit (1) comprises a plurality of battery packs I (11), battery packs II (12), battery packs III (13), a middle beam assembly (14), a connecting water pipe (15), a heat insulation assembly (16), an end plate I assembly (17) and an end plate II assembly (18); the end plate I assembly (17) and the end plate II assembly (18) are respectively arranged at two ends of the super-large battery pack unit (1), the inner sides of the end plate assemblies at the two ends are respectively provided with a battery pack II (12) and a battery pack III (13) in a close fit manner, a plurality of battery packs I (11) and heat insulation assemblies (16) are sequentially and alternately arranged between the battery packs II (12) and the battery packs III (13), and a heat insulation assembly (16) is clamped between the adjacent two groups of battery packs I (11); a middle beam assembly (14) is clamped and fixed between two adjacent groups of the middle parts of the groups of battery packs I (11); the upper end and the lower end of a liquid cooling plate on a plurality of groups of battery packs I (11), the upper end and the lower end of a liquid cooling plate on a battery pack II (12) and the upper end and the lower end of a liquid cooling plate on a battery pack III (13) are respectively connected with a water pipe (15) in series and communicated to form a liquid cooling circulation channel;
each group of battery pack I (11) comprises two battery core groups (111) and a liquid cooling plate I assembly (112), the two battery core groups (111) are respectively arranged at two sides of the liquid cooling plate I assembly (112), and the positive and negative electrodes of the battery cells of the two battery core groups (111) corresponding to the left and right are arranged in the same direction or in the opposite direction; each electric core group (111) comprises electric cores (1111) and a heat insulation pad (1112), the heat insulation pad (1112) is clamped between every two adjacent electric cores (1111), a blue film is coated outside each electric core (1111), and a window is formed at the bottom of the blue film of each electric core (1111); each liquid cooling plate I assembly (112) comprises a liquid cooling plate I (1121) and two heat conducting elements (1122); the two heat conduction elements (1122) are respectively arranged on the left side and the right side of the liquid cooling plate I (1121), each liquid cooling plate I (1121) is an aluminum alloy harmonica tube or a brazed aluminum plate, two ends of each liquid cooling plate I (1121) are respectively fixedly communicated with a three-way pipe I of a battery pack, and the horizontal bidirectional water pipe joint end of the three-way pipe I of the battery pack is a universal joint; each heat conducting element (1122) is formed by adhering double-sided adhesive tapes to two sides of a heat conducting base material;
the battery pack II (12) comprises two electric core groups and a liquid cooling plate II assembly (121) which have the same structure as the battery pack I (11); the second liquid cooling plate component (121) comprises a first liquid cooling plate (1121) and two heat conducting elements (1122), the structure of the first liquid cooling plate component (112) is the same as that of the second liquid cooling plate component (121), the second liquid cooling plate component (121) further comprises two through holes, and two ends of the second liquid cooling plate component (121) are fixedly communicated with the two through holes respectively;
the battery pack III (13) comprises two electric core groups and a liquid cooling plate III assembly (131) which have the same structure as the battery pack I (11), the liquid cooling plate III assembly (131) comprises a liquid cooling plate I (1121) and two heat conducting elements (1122) which have the same structure as the liquid cooling plate I assembly (112), the liquid cooling plate III assembly (131) further comprises two battery pack III tee joints, two ends of the liquid cooling plate III assembly (131) are respectively and fixedly communicated with a battery pack III tee joint, the left end of a horizontal bidirectional water pipe connector of the battery pack III tee joint is a universal connector, and the right end of the horizontal bidirectional water pipe connector of the battery pack III tee joint is a connector matched with the water inlet pipe assembly and the water outlet pipe assembly;
the middle beam assembly (14) comprises a middle beam (141) and a buffer assembly I (142); the buffer assemblies I (142) are arranged on the left side surface and the right side surface of the middle beam (141); the buffer component I (142) is made of an elastic compressible material; the middle beam (141) is a movable beam, two ends of the middle beam are provided with connecting water pipe avoiding openings, and the middle beam is made of light aluminum alloy, aluminum profile or cast aluminum;
the heat insulation assembly (16) comprises a heat insulation element (161) and a buffer assembly I (142), wherein the buffer assembly I (142) is arranged on the left side surface and the right side surface of the heat insulation element (161); the heat insulation element (161) is a hollow metal sealed cavity, and a high specific heat solution is contained in the metal sealed cavity;
the end plate I assembly (17) comprises an end plate I (171) and a buffer assembly II (172); the buffer component II (172) is arranged on one side surface of the end plate I (171); the end plate I (171) is made of a non-metal composite material; the material of the buffer component II (172) is the same as that of the buffer component I (142); the end plate II component (18) comprises an end plate II (181) and a buffer component II (172), the buffer component II (172) is arranged on one side face of the end plate II (181), and the material of the end plate II (181) is the same as that of the end plate I (171);
the liquid cooling pipe integrated battery lower box body (2) comprises a lower box body component (21), a water inlet pipe component (22) and a water outlet pipe component (23); the water inlet pipe assembly (22) and the water outlet pipe assembly (23) are embedded and communicated with an internal pipeline of a right longitudinal side beam (211) of the lower box body assembly (21), the liquid cooling pipe integrated battery lower box body (2) is provided with a glue layer limiting convex edge (212), and the glue layer limiting convex edge (212) is arranged on a bottom plate (213) of the lower box body;
the integrated sampling connection assembly (3) comprises a sampling execution unit (31), an inter-cell busbar (32), an upper protection unit (33) and a lower protection unit (34); the sampling execution unit (31) can be an FPC, a flexible flat cable FFC or an electric wire bundle; the inter-cell bus bar (32) is made of aluminum or copper; the sampling execution unit (31) is connected with the inter-battery-core busbar (32) in a welding mode; and integrating the sampling execution unit (31) and the inter-cell bus bar (32) into a whole by using the upper protection unit (33) and the lower protection unit (34) through a hot pressing process or a bonding mode.
3. A large area cooling cage high battery system according to claim 2, wherein: in super large-size group battery unit (1), thermal-insulated subassembly (16) with middle part roof beam subassembly (14) with I subassembly (112) of liquid cold plate are whole to be replaced, and just every I subassembly (112) of liquid cold plate of replacement communicate with the water pipe head of controlling adjacent liquid cold plate respectively through connecting water pipe (15).
4. A large area cooling cage high battery system according to claim 2, wherein: a plurality of connecting water pipes (15) are respectively communicated with the joints 5 of the upper end and the lower end of the adjacent liquid cooling plate I assembly (112), the joints of the upper end and the lower end of the water pipe of the liquid cooling plate II assembly (121) and the joints of the upper end and the lower end of the water pipe of the liquid cooling plate III assembly (131) to form a main pipeline with the upper end and the lower end; the water pipe joints on the right sides of the upper end and the lower end of the liquid cooling plate III assembly (131) are respectively in seamless connection with the water pipe joints of the water inlet pipe assembly (22) and the water outlet pipe assembly (23) to form an integrally communicated large-area cooling type heat management system (10); the flow direction of the cooling liquid flows into the battery system from the water inlet pipe assembly (22), and the cooling liquid respectively flows into the liquid cooling plate III assembly (131), the liquid cooling plate I assembly (112) 0 and the liquid cooling plate II assembly (121) through the upper end main pipeline, then converges to the lower end main pipeline and flows out of the battery system through the water outlet pipe assembly (23).
5. A large area cooling cage high battery system according to claim 2, wherein: the two ends of the I components (112) of the uniformly distributed liquid cooling plates, the II components (121) of the liquid cooling plates, the III components (131) of the liquid cooling plates, the heat insulation elements (161) and the middle beam (141) are respectively bonded and fixed with the upper transverse side beam (214), the lower transverse side beam (215) and the lower box bottom plate (213) of the lower box component (21) 5 through structural adhesive (7), and a cage-type structure protection system (20) is formed.
6. A large area cooling cage high battery system according to claim 2, wherein: the liquid cooling plate I assembly (112), the liquid cooling plate II assembly (121), the liquid cooling plate III assembly (131), the middle beam (141), the heat insulation element (161) and the heat insulation pad (1112) form a heat insulation 0 protection system (30) and separate all the electric cores independently.
7. A large area cooling cage high battery system according to claim 2, wherein: the buffer component I (142) and the buffer component II (172) jointly form a cell expansion safety protection system (40), the buffer component I (142) is arranged on two side faces of the heat insulation element (161),
the buffer component I (142) is arranged on two side faces of the middle beam (141), the buffer component II (172) 5 is arranged on one side face of the end plate I (171), and the buffer component II (172) is arranged on the end plate II (181)
And one side surface.
8. A large area cooling cage high battery system according to claim 2, wherein: the integrated sampling connection assembly (3) and the battery management system cluster control unit (4) jointly form a direct connection type battery core sampling connection system (50); the battery management system cluster control unit (4) is arranged on one side of the ultra-large-size battery pack unit (1), and the integrated sampling connection assembly (3) is directly connected with the battery management system cluster control unit (4) through a connector.
9. A method of assembling a large area cooling cage type high battery system according to any one of claims 1 to 8, comprising: the method comprises the following steps:
s1: sorting and cleaning the battery cells;
s2: the battery core pole is inverted downwards and then stacked into a battery core group, or the battery core pole is inverted and then stacked into a battery pack, and the battery core pole faces downwards;
s3: the electric core assembly is adhered with the liquid cooling plate assembly to form a battery pack;
s4: stacking an end plate assembly, a battery pack, a heat insulation assembly, a middle beam assembly, a connecting water pipe and the like into an oversized battery pack unit;
s5: after the lower battery box body is coated with structural adhesive, the lower battery box body is turned over at 180 ℃ so that the opening of the lower battery box body is punched down and reversed to advance, and the assembly of the oversized battery pack unit into the box is realized;
s6: after the whole body is clamped, the whole body is turned over at 180 ℃ and is straightened, and the electric core pole is upward;
s7: the integrated sampling connection assembly is welded with the oversized battery pack unit;
s8: the battery management system cluster control unit is fixedly arranged on the battery lower box body, and the integrated sampling connection assembly is directly connected with the battery management system cluster control unit in an opposite insertion mode;
s9: installing an upper box body assembly and an all-in-one system;
s10: and (5) detecting the offline of the battery system.
10. A vehicle, characterized in that: a battery system according to any of claims 1-8 comprising a battery assembled using the battery grouping method according to claim 9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211549598.0A CN115911728A (en) | 2022-12-05 | 2022-12-05 | Large-area cooling cage type structure high-grouping-rate battery system, grouping method and vehicle |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211549598.0A CN115911728A (en) | 2022-12-05 | 2022-12-05 | Large-area cooling cage type structure high-grouping-rate battery system, grouping method and vehicle |
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| CN115911728A true CN115911728A (en) | 2023-04-04 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116632465A (en) * | 2023-07-19 | 2023-08-22 | 中国第一汽车股份有限公司 | Direct-connection battery module, design method thereof, battery pack and vehicle |
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- 2022-12-05 CN CN202211549598.0A patent/CN115911728A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116632465A (en) * | 2023-07-19 | 2023-08-22 | 中国第一汽车股份有限公司 | Direct-connection battery module, design method thereof, battery pack and vehicle |
| CN116632465B (en) * | 2023-07-19 | 2023-10-27 | 中国第一汽车股份有限公司 | Direct-connection battery module, design method thereof, battery pack and vehicle |
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