A battery system and design method

Abstract

The present application relates to a kind of battery system and design method, mainly by lower box assembly and module 1 It is composed of;Lower box assembly includes lower box, water cooling plate;Water cooling plate is directly integrated into lower box, forms lower box assembly;Module is placed into lower box;Lower box includes box, battery beam;Battery beam is connected to box by the form of welding;Battery beam is T-shaped beam;Battery beam cooperates with module;Flow channel, water pipe, inlet and outlet are integrated with the lower box assembly of high integration high safety battery system;The present application provides a kind of battery and vehicle integrated with body function, to fill the design blank in the development of relevant products;The present application improves the safety of whole package, improves the stiffness of whole package, and based on the battery box process of stir friction welding, realizes integrated layout design, and the characteristics of high degree of generalization of different vehicle platforms, greatly improves development efficiency and reduces development cost.

Description

TECHNICAL FIELD

[0001] The application relates to a battery system and a design method. BACKGROUND

[0002] There are many technologies for integrating existing battery packs with vehicle bodies.

[0003] For example, patent No. CN201710992015.4 discloses an electric vehicle and a vehicle body structure thereof, which mainly uses the vehicle body floor as an upper cover of the battery pack, assembles a lower shell of the battery with the vehicle body floor, and mainly describes the structural form, without detailed description of the control system and the internal structure of the battery pack. The application is different from the prior art in structure, controller position and the like.

[0004] Patent No. CN203293886U discloses a battery vehicle chassis, which is integrated with the vehicle body to the maximum extent based on a traditional power battery to reserve more space. The application patent is to use the vehicle body as a box structure of the battery pack to realize maximum integration with the vehicle body.

[0005] Patent No. CN201710992015.4 discloses an electric vehicle and a vehicle body structure thereof, which mainly focuses on the vehicle body structure and does not describe the internal arrangement of the battery pack. The vehicle body is obviously a sheet metal welded vehicle body, and the application is not limited to sheet metal but can use other materials to form a battery compartment to improve the space utilization of the vehicle body cavity and the passenger compartment.

[0006] Patent No. CN201721173539.2 describes a new type of cast aluminum battery box of a new energy electric vehicle, which mainly has the characteristics of integrally casting the box and internally having a plurality of longitudinal and transverse reinforcing ribs. The application is different from the prior art in that it mainly describes the generality, welding and integration of the cast aluminum box. SUMMARY

[0007] The existing electric vehicle power battery pack module integration bearing structure is a cooling plate bearing. With the operation of the vehicle, the liquid cooling plate itself is damaged, or cannot withstand the weight of the battery cell and is damaged, which brings safety hazards. To solve the problem, the application provides a high-integration and high-safety battery system and method, relates to a new type of battery cell bearing structure, and the liquid cooling plate does not need to bear the weight of the battery cell, but distributes the weight of the battery cell on the beam and realizes integrated integration. The application mainly includes a high-low voltage connecting part, a box and the like, has no scattered parts in the box, has high generalization degree for different vehicle platforms, greatly improves the development efficiency, reduces the development cost and guarantees the safety of the battery pack.

[0008] The application provides a high-integration and high-safety battery system and method, realizes a high-integration and high-safety integration scheme of a battery pack, solves the problems as above, and improves the safety of the whole pack.

[0009] It should be noted that, in this document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0010] To solve the above technical problems, the application is realized by adopting the following technical scheme:

[0011] A battery system mainly comprises a lower box assembly and a module 1; the lower box assembly comprises a lower box 3 and a water-cooling plate 5; the water-cooling plate 5 is directly integrated to the lower box 3 to form the lower box assembly; the module 1 is put into the lower box 3.

[0012] Further, the lower box 3 comprises a box 3.1 and a battery beam 3.2; the battery beam 3.2 is connected to the box 3.1 by welding.

[0013] Further, the battery beam 3.2 is a T-shaped beam.

[0014] Further, the width of the T-shaped beam is in the range of 5mm to 20mm, the transition angle of the tip head of the T-shaped beam is in the range of 90° to 160°, the thickness of the T-shaped beam is in the range of 2mm to 5mm, and the transition angle of the root position of the T-shaped beam is in the range of 90° to 160°.

[0015] Further, the battery beam 3.2 cooperates with the module 1.

[0016] Further, an insulating strip 4 is bonded on the battery beam 3.2, and a heat-conducting structural adhesive is arranged on the water-cooling plate 5 before the module is put into the box.

[0017] The height of the heat-conducting structural adhesive is higher than the height of the T-shaped beam and is leveled with the height of the insulating strip 4, and an adhesive layer is formed between the module and the battery cell.

[0018] A battery system design method is provided, and a flow channel 3.5, a water pipe, an inlet and an outlet are integrated with the lower box assembly of the battery system.

[0019] Further, the lower box 3 periphery connection adopts the friction stir welding - butt welding process connection, and the middle position adopts the friction stir welding - lap welding process;

[0020] The air tightness after welding meets the requirement effect of ≥200kpa.

[0021] Further, the flow channel, water pipe and water inlet and outlet are integrated in one;

[0022] The flow channel is integrally formed with the box body and forms a sealed fluid domain by cooperating with the liquid cooling plate;

[0023] The lower box is integrated with a module, a low-voltage wire harness, a high-voltage wire harness, a battery management system and a high-voltage management system;

[0024] The lower box is designed as a boss or a threaded hole, and is integrally cast and machined in one process.

[0025] Further, the water pipe and the water inlet and outlet are in circular or square form; the wall thickness of the water pipe is between 1.5 and 3.0 mm, and the cross-sectional area of the water inlet and outlet is greater than or equal to 100 square millimeters;

[0026] The flow direction of the flow channel is perpendicular to the arrangement direction of the battery cells;

[0027] The flow channel is provided with different length and angle disturbance points at the water inlet and outlet and the corners of the lower box, so as to realize fluid distribution and ensure the uniformity of fluid flow.

[0028] Compared with the prior art, the present application has the following advantages:

[0029] The present application provides a high-integration and high-safety battery system and method, realizes a high-integration and high-safety integration scheme of the battery pack, and provides a battery and vehicle with integrated functions of the whole pack and vehicle body, which fills the design gap in the development of related products.

[0030] The present application improves the safety of the whole pack, improves the rigidity of the whole pack, and realizes integrated arrangement design based on the battery box process of friction stir welding, has high degree of generalization for different vehicle platforms, greatly improves the development efficiency and reduces the development cost. BRIEF DESCRIPTION OF DRAWINGS

[0031] The present application will be further described below with reference to the accompanying drawings:

[0032] Figure 1 is a battery system structure diagram according to the present application;

[0033] Figure 2 is a T-shaped beam schematic diagram;

[0034] Figure 3 is a box schematic diagram;

[0035] Figure 4 is Figure 3 cross-sectional view at A-A in FIG.

[0036] in the figure:

[0037] 1, module;

[0038] 2, controller;

[0039] 3, lower box body;

[0040] 3.1, box body

[0041] 3.2, battery beam;

[0042] 3.2.1, width of T-shaped beam;

[0043] 3.2.2, transition angle of T-shaped beam tip head;

[0044] 3.2.3, T-shaped beam thickness;

[0045] 3.2.4, transition angle of T-shaped beam root position;

[0046] 3.3.1, water inlet;

[0047] 3.3.2, water outlet;

[0048] 3.4, mounting features in high-pressure interface integrated box body;

[0049] 3.5, flow channel

[0050] 4, insulation strip;

[0051] 5, water-cooled plate; DETAILED DESCRIPTION

[0052] In order to make the purpose, technical scheme and advantages of the present application clearer, the technical scheme of the embodiments of the present application will be described in more detail below in combination with the drawings of the embodiments of the present application. In the drawings, the same or similar reference numerals represent the same or similar elements or elements having the same or similar functions throughout. The described embodiments are part of the embodiments of the present application, not all embodiments. The embodiments described below by reference to the drawings are exemplary and are intended to explain the present application, and cannot be understood as limiting the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application. The embodiments of the present application will be described in detail below in combination with the drawings.

[0053] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore cannot be understood as a limitation on the scope of protection of the present application.

[0054] The present application will be described in detail below in conjunction with the drawings:

[0055] The power battery system is mainly composed of a lower box assembly and a square cell module. The lower box assembly includes longitudinal beams, transverse beams and a water cooling plate, wherein the water cooling plate is directly integrated into the longitudinal beams and the transverse beams to form the lower box.

[0056] The transverse beams and the longitudinal beams are connected by welding. The transverse beams and the longitudinal beams are profile extrusion schemes.

[0057] The power battery is integrally cast with a T-shaped beam structure. The T-shaped beam has good rigidity and improves the carrying capacity of the battery pack. The root of the T-shaped beam is Figure 2 .

[0058] The width of the T-shaped beam is in the range of 5mm to 20mm, the transition angle of the tip head of the T-shaped beam is in the range of 90° to 160°, the thickness of the T-shaped beam is in the range of 2mm to 5mm, and the transition angle of the root position of the T-shaped beam is in the range of 90° to 160°.

[0059] After the module, the frame and the liquid cooling plate are integrally formed into the lower box assembly, the T-shaped beam cooperates with the module after the module is put into the box.

[0060] An insulating strip needs to be bonded on the T-shaped beam. Before the module is put into the box, the water cooling plate of the lower box needs to have a heat-conducting structural adhesive.

[0061] The height of the heat-conducting structural adhesive is higher than the height of the T-shaped beam and is level with the height of the insulating strip, forming a bonding layer between the module and the cell.

[0062] The battery box based on friction stir welding and the design method include a box body, a lifting lug, a liquid cooling plate, a flow channel, a water pipe, a water inlet, a sealing gasket and a bottom guard plate. The flow channel, the water pipe and the water inlet are integrated with the box body.

[0063] The box body only needs one set of mold for different vehicle models, and the vehicle models with different configurations are machined or increased with sliding blocks.

[0064] The thermal management system includes the flow channel, the water pipe and the water inlet of the box body, and the liquid cooling plate is connected with the cast box body by using the friction stir welding-butt welding process in the peripheral connection and the friction stir welding-lap welding process in the middle position.

[0065] The welding quantity can be welded or saved according to the actual heat management pressure, and the air tightness after welding meets the effect of ≥200kpa requirement.

[0066] The battery box based on friction stir welding and the arrangement method can realize the idea of few-piece integration based on the existing process, realize the idea of integration and selection, few pieces and few pieces, and never redundant design.

[0067] The design scheme is that the overall skew angle is 1° to 3°, the material is selected to have high elongation and high strength, and the effect meets the performance requirements of the battery national standard.

[0068] The support-free design is adopted in the box body, but the reinforcing ribs are increased to meet the extrusion performance requirements of the national standard. Based on the consideration of the material itself, holes can be directly opened in the box body to directly connect the connected parts and the box body, and the external runner plate and the box body are friction stir welded.

[0069] It includes friction stir welding-butt welding, friction stir welding, and friction stir welding for different friction welding parameters.

[0070] The battery thermal management system includes a runner, a water pipe, and a water outlet integrated into one, realizing high integration.

[0071] The runner is integrally formed with the box body and forms a sealed fluid domain by cooperating with the liquid cooling plate.

[0072] The body integrates the water pipe and the water outlet functions, reducing the number of parts.

[0073] The water pipe and the water outlet can be circular, square, etc., and can be adapted according to the heat management requirements. The wall thickness of the water pipe is between 1.5 and 3.0 mm, and the cross-sectional area of the water outlet is greater than or equal to 100 square millimeters.

[0074] The battery thermal management device and the arrangement method include a runner structure and an arrangement position, and the effect is to improve the heat exchange efficiency and prevent flow dead zones.

[0075] The flow direction of the runner is perpendicular to the arrangement direction of the battery cells, effectively reducing the temperature difference between different battery cells.

[0076] The runner is provided with different length and angle disturbance points at the inlet and outlet of the water outlet and the corners of the box body, realizing the flow of the fluid, and ensuring the uniformity of the fluid flow.

[0077] The battery box based on friction stir welding and the design method include the design of no redundant fixed support in the box body, which can highly integrate the installation points of the module, the low-voltage wire harness, the high-voltage wire harness, the battery management system, and the high-voltage management system.

[0078] The box is designed as a boss or a threaded hole, is integrally cast and is machined in one process, so that the machining difficulty of the product itself is reduced, and the assembly precision of the whole battery pack is improved.

[0079] The application provides a high-integration high-safety battery system and a design method.

[0080] A battery system mainly comprises a lower box assembly, a module 1 and a controller 2; the lower box assembly comprises a lower box 3 and a water-cooling plate 5; the water-cooling plate 5 is directly integrated into the lower box 3 to form the lower box assembly; the module 1 and the controller 2 are placed into the lower box 3.

[0081] The battery system is related to the box 3.1, the battery beam 3.2 and a beam not shown; after the beam 3.2 with a bracket is sprayed with insulating paint, an insulating strip 4 is bonded, the water-cooling plate 5 is assembled below the bracket, the module 1 is placed into the box after the assembly is formed, and the battery system is as follows Figure 1 It is a schematic diagram of the whole system, Figure 2 It is a schematic diagram of the beam 3.2 with a bracket feature; 3.2.1 is the width of the T-shaped beam, that is, the width of the loadable battery cell, which is flexibly designed according to the battery cell; 3.2.2 is the transition angle of the head of the T-shaped beam, the head of the T-shaped beam directly contacts the battery cell; 3.2.3 is the thickness of the T-shaped beam, which is determined according to the weight of the loadable battery cell; and 3.2.4 is the transition angle of the root position of the T-shaped beam, which can maximize the strength of the T-shaped beam, Figure 3 It is a way of integrating the beam 3.2 in Figure 1 into the box 3.1, and the water-cooling plate 5 in Figure 1 is changed into a water-cooling lower plate, wherein the water-cooling upper plate is integrated into the box 3.1, and the beam 3.2 feature in Figure 2 is embodied in another scheme, Figure 4 It is the feature of the integrated box, and embodies the water inlet 3.3.1, the water outlet 3.3.2 and the flow channel feature 3.5.

[0082] Figure 1 and Figure 4 It is a schematic diagram of the friction stir welding feature.

[0083] Figure 1 3.4 in Figure 3 and 3.4 in are mounting features of the high-pressure interface integrated into the box.

[0084] The application provides a high-integration high-safety battery system and a method, which comprise an integrated scheme of a battery module, a T-shaped beam and a water-cooling plate, compared with the prior art, the bearing structure of the existing electric vehicle power battery pack module integration mode is a cooling plate bearing; with the operation of the vehicle, the liquid cooling plate itself can be damaged, or cannot bear the weight of the battery cell and is damaged, thereby bringing safety hazards.

[0085] The application relates to a battery box based on friction stir welding and a design method, which comprises a box body, lifting lugs, a liquid cooling plate, a flow channel, a water pipe, a water inlet, a sealing gasket and a bottom guard plate, the flow channel, the water pipe and the water inlet are integrated with the box body, only one set of molds is needed for different vehicle models, and machining or a slider form is added for different vehicle models.

[0086] The heat management system comprises the flow channel, the water pipe and the water inlet of the box body, and the liquid cooling plate is connected with the peripheral circle of the cast box body through a friction stir welding-butt welding process, and the middle position is connected through a friction stir welding-lap welding process.

[0087] The effect is that the body is integrally formed, an open battery assembly cabin is formed, and the battery cabin has high integration and strong generalization.

[0088] The effect is that the body can be made of aluminum or steel, the lifting lugs, the flow channel, the water pipe, the water inlet and the connector interface are different according to different vehicle forms, the body is integrally formed through an integrated process, the platform has high utilization rate, and development cost is saved.

[0089] The welding quantity can be welded at multiple positions according to actual heat management pressure or saved, and the air tightness after welding meets the requirement of greater than or equal to 200 kpa.

[0090] The heat management system has the characteristics of high integration with the lower box body and low cost.

[0091] The effect is that in the box body, the flow channel, the water pipe and the water inlet share only one set of molds for different vehicle models, at least three or more vehicle models are used, development progress is greatly reduced, and development cost is saved.

[0092] The application relates to a battery box based on friction stir welding and a layout method, based on an existing process, a few-piece integration idea can be realized, an integrated selection idea can be realized, a few-piece selection idea can be realized, and a non-redundant design idea is never used, the overall inclination angle of the design scheme is 1 to 3 degrees, a material with high elongation and high strength is selected, and the effect meets the performance requirements of a battery national standard.

[0093] A support is not used in the box body, but a reinforcing rib is added to meet the extrusion performance requirements of the national standard, based on material itself, a hole can be directly formed in the box body to directly connect a connected piece with the box body, the outer flow channel plate and the box body are connected through friction stir welding, the friction stir welding includes butt welding, friction stir welding and lap welding, and the friction stir welding is matched and designed according to different friction welding parameters. Finally, the goals of integration, few pieces, high strength, high reliability and high safety are realized.

[0094] The application relates to a battery heat management system, which comprises a flow channel, a water pipe and a water inlet feature integrated in one piece, and high integration is realized.

[0095] The flow channel is integrally formed with the box body and forms a closed fluid area by cooperating with the liquid cooling plate.

[0096] The body integrates a water pipe and a water gap function, thereby reducing parts.

[0097] The water pipe and the water gap feature can be circular, square or other forms, and can be adapted according to the heat management requirement, the wall thickness of the water pipe is between 1.5-3.0mm, and the cross-sectional area of the water gap is greater than or equal to 100 square millimeters.

[0098] The effect is to reduce the machining process and save time, and to realize dry and wet separation with the battery pack, avoid leakage risk and improve product safety.

[0099] The application relates to a battery heat management device and arrangement, including a flow channel structure and arrangement position, and has the effects of improving heat exchange efficiency and preventing flow dead zones.

[0100] The flow direction of the flow channel is perpendicular to the arrangement direction of the battery cell, so that the temperature difference between different battery cells is effectively reduced.

[0101] The flow channel is provided with different length and angle disturbance points at the inlet and outlet of the water gap and the corners of the box body, so as to realize fluid distribution and ensure the uniformity of fluid flow.

[0102] The above is only a specific embodiment of the application, but the protection scope of the application is not limited to this, any skilled person in the art can make any modification, equivalent replacement and improvement within the technical range disclosed in the application, as long as it is within the spirit and principle of the application, and all of the above should be covered in the protection scope of the application. Meanwhile, the contents not described in detail in the specification are all the existing technology known to those skilled in the art.

Claims

1. A battery system, characterized by: Mainly by the lower box assembly, module (1) composition, the lower box assembly includes lower box (3), water cooling plate (5), the water cooling plate (5) is directly integrated to the lower box (3), forms the lower box assembly, the module (1) is put into the lower box (3) inside, The lower box (3) includes box (3.1), battery beam (3.2), the battery beam (3.2) is connected to the box (3.1) by welding, The battery beam (3.2) is T-shaped beam, The battery beam (3.2) cooperates with the module (1).

2. The battery system according to claim 1, wherein: The width of the T-shaped beam is in the range of 5mm to 20mm, the transition angle of the T-shaped beam tip head is in the range of 90° to 160°, the thickness of the T-shaped beam is in the range of 2mm to 5mm, and the transition angle of the T-shaped beam root position is in the range of 90° to 160°.

3. The battery system according to claim 2, wherein: An insulating strip (4) is bonded on the battery beam (3.2), and a heat-conducting structural adhesive is provided on the water cooling plate (5) before the module is put into the box; The height of the heat-conducting structural adhesive is higher than the height of the T-shaped beam and is level with the height of the insulating strip (4).

4. A battery system design method characterized by: A flow channel (3.5), a water pipe, an inlet and outlet are integrated with the lower box assembly of the battery system; The flow channel, the water pipe and the inlet and outlet are integrally integrated; The flow channel is integrally formed with the box and forms a closed fluid domain by cooperating with the liquid cooling plate; The lower box integrates the module, the low-voltage wire harness, the high-voltage wire harness, the battery management system and the high-voltage management system in height; The lower box is designed with a boss or a threaded hole.

5. The battery system design method according to claim 4, wherein: The lower box (3) is connected by using a friction stir welding-butting welding process at the periphery and a friction stir welding-lap welding process at the middle position; After welding, the air tightness meets the requirement of ≥200kpa.

6. The battery system design method according to claim 5, wherein: The water pipe and the inlet and outlet are in circular or square form; the wall thickness of the water pipe is between 1.5 and 3.0mm, and the cross-sectional area of the inlet and outlet is greater than or equal to 100 square millimeters; The flow direction of the flow channel is perpendicular to the arrangement direction of the battery cells; The flow channel is provided with different length and angle disturbance points at the inlet and outlet and the corners around the lower box to realize fluid distribution and ensure the uniformity of fluid flow.

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