High protection level air-cooled battery pack

Abstract

The application discloses a novel high-protection-grade air-cooled battery pack, which comprises a battery pack cover, a heat dissipation structure side plate, a welding fixing support, an end connecting plate and a battery module heat dissipation plate. The battery pack adopts an internal structure of lower battery modules and upper electric appliance plates, can independently select the number of tailor-welded shells, and forms battery shells with different sizes. The number of battery cells in the modules can be changed, so that battery packs with different capacities can be formed. The heat of the battery cells is conducted to the shell heat dissipation fins through the heat dissipation plate or glue coating, and the heat is led out of the battery pack. The whole battery pack is in a sealed state and can be in contact with the shell for heat dissipation. The air-cooling strengthens the heat dissipation effect and can adapt to a high-temperature and high-humidity working environment.

Description

Technical Field

[0001] This invention relates to the field of new energy battery technology, and in particular to a high-protection-level air-cooled battery pack. Background Technology

[0002] Currently, key technologies for power batteries are maturing and are widely used in electric vehicles and special-purpose vehicles. Due to the high energy density and high charging rate advantages of lithium batteries, their share in the forklift market is gradually increasing. However, forklifts operate in complex environments; in high-temperature conditions, the lifespan and range of lithium batteries are significantly reduced, thus requiring battery pack cooling. Workshop environments are variable, often requiring outdoor operations, and some workshops have high dust levels, necessitating high-standard protection for battery packs. Currently, most lithium-ion forklifts on the market use natural cooling or open-air cooling, which does not meet the needs of working in special areas.

[0003] Naturally cooled forklift battery packs – These battery packs are completely sealed and do not have an added cooling device, relying on natural cooling. The drawback is that in high-temperature areas or hot summers, high-temperature operation can cause a decrease in battery capacity or a reduction in battery life.

[0004] Open-type air-cooled forklift battery packs – These battery packs are not sealed; a fan is added to cool them, allowing them to operate within a suitable temperature range. However, they suffer from severe corrosion in high-humidity areas, drastically reducing their lifespan. Water can easily enter during cleaning or use, leading to short circuits and lowering operator safety.

[0005] Water-cooled forklift battery packs use water pumps and cooling pipes to control the temperature inside the battery pack; the disadvantages are higher cost, the need for water cooling pipes and external water pumps, and larger space requirements. Summary of the Invention

[0006] This invention addresses the problems existing in the prior art by creatively designing a high-protection-level air-cooled battery pack. It adopts an internal structure with a lower battery module and an upper electrical board. The battery pack is connected to the BMS, which can remotely transmit location information and real-time status information of the battery pack in real time. It adopts a split-wiring design, with separate lines for the charging connector and the discharging connector, and separate control, which improves the overall safety factor of the battery pack.

[0007] The technical solution adopted to achieve the present invention is: a high-protection-level air-cooled battery pack, characterized in that it includes: a battery pack cover 6, a heat dissipation structure side plate 7, a welding fixing bracket 8, an end connecting plate 16, and a battery module heat dissipation plate 23. A group of the battery module heat dissipation plates 23 are arranged and connected in sequence, and the first connecting plate 25 of the battery module heat dissipation plates 23 is fixedly connected. End connecting plates 16 are respectively provided at both ends of the group of battery module heat dissipation plates 23, and the second connecting plate 32 of the end connecting plate 16 is fixedly connected to the first connecting plate 25 of the battery module heat dissipation plate 23. Heat dissipation structure side plates 7 are respectively provided on both sides of the heat dissipation plate 23 of the battery module. The heat dissipation structure side plates 7 are fixedly connected to the end connecting plate 16. Welded fixing brackets 8 are respectively provided on both sides of the lower part of the heat dissipation structure side plates 7. The welded fixing brackets 8 are fixedly connected to the heat dissipation structure side plates 7. The first battery pack cover connecting plate 29 and the second battery pack cover connecting plate 33 of the heat dissipation structure side plates 7 are on the same plane. The battery pack cover 6 is threadedly connected to the first battery pack cover connecting plate 29 and the second battery pack cover connecting plate 33 respectively.

[0008] Furthermore, it also includes: a connecting panel 15, which is provided on the upper part of the battery module heat sink 23, and the connecting panel 15 is threadedly connected to the heat sink structure side plate 7.

[0009] Furthermore, it also includes a battery module 9, which comprises: a metal strap 17, a battery module side plate 18, a battery module end plate 19, a current-guiding copper busbar 20, a square battery cell 21, and a bottom adhesive coating 22. The battery module end plate 19 is respectively provided on the front and rear sides of the square battery cell 21, the battery module side plate 18 is respectively provided on the left and right sides of the square battery cell 21, the metal strap 17 is provided on the outside of the battery module end plate 19 and the battery module side plate 18, the bottom adhesive coating 22 is provided on the bottom of the square battery cell 21, and the current-guiding copper busbar 20 is provided on the upper part of the square battery cell 21. The battery module 9 is disposed inside the battery module heat sink 23.

[0010] Furthermore, the battery module heat sink 23 includes: a U-shaped plate 24, a first connecting plate 25, a first heat sink 26, and a base support plate 27. The base support plate 27 is respectively provided at the four corners of the bottom of the U-shaped plate 24. A set of first heat sinks 26 is provided on the outside of the U-shaped plate 24. The first heat sinks 26 are fixedly connected to the U-shaped plate 24. The first connecting plate 25 is respectively provided on the two upper edges of the U-shaped plate 24.

[0011] Furthermore, the end connecting plate 16 includes: a base support plate 27, an end connecting U-shaped plate 28, a first battery pack cover connecting plate 29, a battery pack mounting hole 30, a second connecting plate 31, and a second heat sink 32. The base support plate 27 is provided at the bottom of the end connecting U-shaped plate 28. The first battery pack cover connecting plate 29 is provided on the upper edge of one side of the end connecting U-shaped plate 28. The second connecting plate 31 is provided on the upper edge of the other side of the end connecting U-shaped plate 28. A set of second heat sinks 32 are sequentially provided at the lower part of the second connecting plate 31. The second heat sinks 32 are fixedly connected to the end connecting U-shaped plate 28. The battery pack mounting hole 30 is provided on the upper edge of one side of the end connecting U-shaped plate 28.

[0012] The beneficial effects of this invention's high-protection-level air-cooled battery pack are reflected in the following aspects:

[0013] A high-protection-level air-cooled battery pack allows for the selection of the number of welded outer shells to form battery casings of different sizes. By changing the number of cells in the modules, battery packs of different capacities can be assembled. It features a relatively inexpensive and safe air-cooled structure. The heat from the cells is conducted to the heat sink on the outer shell through a heat dissipation plate or adhesive coating, and the heat is dissipated from the battery pack. The entire battery pack is in a sealed state, and heat can also be dissipated through contact with the outer shell. The air cooling enhances the heat dissipation effect and can adapt to high-temperature and high-humidity working environments. Attached Figure Description

[0014] Figure 1 This is a three-dimensional view of a high-protection-level air-cooled battery pack;

[0015] Figure 2 yes Figure 1 3D view after removing part 6;

[0016] Figure 3 yes Figure 1 A 3D view of component 9;

[0017] Figure 4 yes Figure 1 Exploded view of component 9;

[0018] Figure 5 This is a three-dimensional view of the frame of a high-protection-level air-cooled battery pack;

[0019] Figure 6 yes Figure 5 A 3D view of component 23;

[0020] Figure 7 yes Figure 5 A 3D view of component 16;

[0021] Figure 8 yes Figure 5 A 3D view of component 7;

[0022] Figure 9 This is a schematic diagram of an air-cooled battery pack with a high protection level.

[0023] In the diagram: 1. Low-voltage output connector, 2. Battery pack information display screen, 3. Battery pack switch button, 4. GPS module, 5. Charging / discharging connector, 6. Battery pack cover, 7. Heat dissipation structure side plate, 8. Welded mounting bracket, 9. Battery module, 10. Shunt, 11. Charging and discharging relay, 12. DC-DC converter, 13. Fuse, 14. BMS control system, 15. Connection panel, 16. End connection plate, 17. Metal strap. 18. Battery module side plate; 19. Battery module end plate; 20. Current-conducting copper busbar; 21. Square battery cell; 22. Underlying adhesive coating; 23. Battery module heat sink; 24. U-shaped plate; 25. First connecting plate; 26. First heat sink; 27. Base support plate; 28. End connecting U-shaped plate; 29. ​​First battery pack cover connecting plate; 30. Battery pack mounting hole; 31. Second connecting plate; 32. Second heat sink; 33. Second battery pack cover connecting plate. Detailed Implementation

[0024] The following is in conjunction with the appendix Figure 1-9 The present invention will be further described in detail with reference to specific embodiments. The specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0025] As attached Figure 1 As shown, the battery pack adopts a traditional square shape for easy matching with forklift bodies. It features a separate wiring design, with separate leads and controls for the charging and discharging connectors, improving the overall safety of the battery pack. This also prevents the discharging end from being loosened due to prolonged plugging and unplugging, which could lead to poor contact and affect safe production. The low-voltage output connector 1 connects to the power fan and other control interfaces and test interfaces outside the battery pack, such as connecting to the forklift's power warning buzzer and warning lights. The display screen 2 mainly displays the real-time status and error codes of the battery pack, facilitating real-time observation and maintenance. The main power switch 3 can cut off the power in case of long-term inactivity or emergency. The GPS module 4 connects to the BMS (Battery Management System) inside the battery pack, enabling real-time remote transmission of location and battery pack status information. The charging (discharging) connectors 5 are fixed above the battery pack cover 6, allowing for easy insertion and removal by the operator. A unique heat dissipation structure and airflow utilize heat sinks to increase the heat dissipation area. The welded fixing bracket 8 can be adjusted in position according to different forklift battery compartments.

[0026] As attached Figure 1 Appendix Figure 2 Appendix Figure 5 and attached Figure 8As shown, a high-protection-level air-cooled battery pack includes: a battery pack cover 6, a heat dissipation structure side plate 7, a welding fixing bracket 8, a connecting panel 15, an end connecting plate 16, and a battery module heat dissipation plate 23. A group of battery module heat dissipation plates 23 are arranged sequentially and connected. The first connecting plate 25 of the battery module heat dissipation plate 23 is fixedly connected. End connecting plates 16 are respectively provided at both ends of the group of battery module heat dissipation plates 23. The second connecting plate 32 of the end connecting plate 16 is fixedly connected to the first connecting plate 25 of the battery module heat dissipation plate 23. Heat dissipation structure side plates 7 are respectively provided on both sides of the group of battery module heat dissipation plates 23. The heat dissipation structure side plates 7 are fixedly connected to the end connecting plates 16. Welding fixing brackets 8 are respectively provided on both sides of the lower part of the heat dissipation structure side plates 7. The welding and fixing bracket 8 is fixedly connected to the heat dissipation structure side plate 7. The first battery pack cover connecting plate 29 and the second battery pack cover connecting plate 33 of the heat dissipation structure side plate 7 are on the same plane. The battery pack cover 6 is threadedly connected to the first battery pack cover connecting plate 29 and the second battery pack cover connecting plate 33 respectively. A connecting panel 15 is provided on the upper part of the battery module heat dissipation plate 23. The connecting panel 15 is threadedly connected to the heat dissipation structure side plate 7. A shunt, charging and discharging relay 11, DC-DC relay 12, fuse 13, and BMS control system 14 are provided on the connecting panel 15. A low-voltage output connector 1, a battery pack information display screen 2, a battery pack switch button 3, a GPS module 4, and a charging and discharging connector 5 are provided on the battery pack cover 6.

[0027] Shunt 10 measures the high-voltage current and provides it to the BMS for calculation; a Hall sensor can also be used instead. Charging (discharging) relay 11 controls the on / off state of the relay through the BMS to achieve automatic control of the high-voltage charging and discharging circuit. DC-DC converter 12 converts the high voltage to a 12V / 24V voltage that can be used by the controller or relay. High-voltage fuse 13 protects the safety of the electrical circuit. BMS controller 14 is the core component of the battery pack control system.

[0028] As attached Figure 3-4 As shown, the battery module 9 includes: a metal strap 17, a battery module side plate 18, a battery module end plate 19, a current-guiding copper busbar 20, a square battery cell 21, and a bottom adhesive coating 22. The battery module end plate 19 is respectively provided on the front and rear sides of the square battery cell 21, the battery module side plate 18 is respectively provided on the left and right sides of the square battery cell 21, the metal strap 17 is provided on the outside of the battery module end plate 19 and the battery module side plate 18, the bottom adhesive coating 22 is provided on the bottom of the square battery cell 21, the current-guiding copper busbar 20 is provided on the upper part of the square battery cell 21, and the battery module 9 is disposed inside the battery module heat sink 23.

[0029] As attached Figure 6As shown, the battery module heat sink 23 includes: a U-shaped plate 24, a first connecting plate 25, a first heat sink 26, and a base support plate 27. The base support plate 27 is respectively provided at the four corners of the bottom of the U-shaped plate 24. A set of first heat sinks 26 is provided on the outside of the U-shaped plate 24. The first heat sinks 26 are fixedly connected to the U-shaped plate 24. The first connecting plate 25 is respectively provided on the two upper edges of the U-shaped plate 24.

[0030] As attached Figure 7 As shown, the end connecting plate 16 includes: a base support plate 27, an end connecting U-shaped plate 28, a first battery pack cover connecting plate 29, a battery pack mounting hole 30, a second connecting plate 31, and a second heat sink 32. The base support plate 27 is provided at the bottom of the end connecting U-shaped plate 28. The first battery pack cover connecting plate 29 is provided on the upper edge of one side of the end connecting U-shaped plate 28. The second connecting plate 31 is provided on the upper edge of the other side of the end connecting U-shaped plate 28. A set of second heat sinks 32 are sequentially provided at the lower part of the second connecting plate 31. The second heat sinks 32 are fixedly connected to the end connecting U-shaped plate 28. The battery pack mounting hole 30 is provided on the upper edge of one side of the end connecting U-shaped plate 28.

[0031] The heat dissipation control logic of this invention is as follows:

[0032] Press the start button, and the battery pack begins to work;

[0033] The BMS (Battery Management System) collects real-time temperatures at various locations within the battery cells of the battery pack using temperature sensors.

[0034] As attached Figure 9 As shown, when the battery temperature exceeds 50°C, the relay at the power fan outside the battery pack controlled by the BMS is activated, and the fan starts working. Figure 8 The airflow in the direction shown in the image begins to cool the area.

[0035] When the battery temperature is below 35°C, the BMS controls the power fan to stop working and stop cooling.

[0036] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high protection level air-cooled battery pack comprising: The battery pack cover (6), the heat dissipation structure side plate (7), the welding fixed support (8), the end connecting plate (16), the battery module heat dissipation plate (23), a group of battery module heat dissipation plates (23) are sequentially arranged and connected, the first connecting plate (25) of the battery module heat dissipation plate (23) is fixedly connected, the end connecting plate (16) is arranged at both ends of the group of battery module heat dissipation plates (23) respectively, the second connecting plate (31) of the end connecting plate (16) is fixedly connected with the first connecting plate (25) of the battery module heat dissipation plate (23), the heat dissipation structure side plate (7) is arranged at both sides of the group of battery module heat dissipation plates (23) respectively, the heat dissipation structure side plate (7) is fixedly connected with the end connecting plate (16), characterized in that the welding fixed support (8) is arranged at both sides of the lower part of the heat dissipation structure side plate (7) respectively, the welding fixed support (8) is fixedly connected with the heat dissipation structure side plate (7), the first battery pack cover connecting plate (29) of the heat dissipation structure side plate (7) is in the same plane as the second battery pack cover connecting plate (33) of the heat dissipation structure side plate (7), the battery pack cover (6) is threadedly connected with the first battery pack cover connecting plate (29) and the second battery pack cover connecting plate (33) respectively, the battery module (9) is arranged in the battery module heat dissipation plate (23), and the battery module heat dissipation plate (23) comprises a U-shaped plate (24), a first connecting plate (25), a first heat dissipation fin (26) and a base support plate (27).

2. The high protection grade air-cooled battery pack according to claim 1, characterized in that, It further comprises a connecting panel (15) arranged on the upper part of the battery module heat dissipation plate (23), and the connecting panel (15) is threadedly connected with the heat dissipation structure side plate (7).

3. The high protection grade air-cooled battery pack of claim 1, wherein, It further comprises a battery module (9), and the battery module (9) comprises a metal binding belt (17), a battery module side plate (18), a battery module end plate (19), a flow guide copper bar (20), a square electric core (21), a bottom layer of glue (22), the battery module end plate (19) is arranged at the front and rear sides of the square electric core (21) respectively, the battery module side plate (18) is arranged at the left and right sides of the square electric core (21) respectively, the metal binding belt (17) is arranged outside the battery module end plate (19) and the battery module side plate (18), the bottom layer of glue (22) is arranged at the bottom of the square electric core (21), and the flow guide copper bar (20) is arranged at the upper part of the square electric core (21).

4. The high protection grade air-cooled battery pack of claim 1, wherein, The end connecting plate (16) comprises: a base support plate (27), an end connecting U-shaped plate (28), a first battery pack cover connecting plate (29), a battery pack hoisting hole (30), a second connecting plate (31), and a second heat sink (32). The base support plate (27) is arranged at the bottom of the end connecting U-shaped plate (28). The first battery pack cover connecting plate (29) is arranged along the edge on one side of the end connecting U-shaped plate (28). The second connecting plate (31) is arranged along the edge on the other side of the end connecting U-shaped plate (28). A group of second heat sinks (32) are sequentially arranged at the lower part of the second connecting plate (31). The second heat sinks (32) are fixedly connected with the end connecting U-shaped plate (28). The battery pack hoisting hole (30) is arranged along the edge on one side of the end connecting U-shaped plate (28).

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