A heat-insulating case for a battery device and a method of mounting the same

Abstract

The application relates to a heat preservation box suitable for a battery device and a mounting method thereof, and belongs to the technical field of heat preservation boxes, which solves the problems of poor strength and poor heat preservation performance of the heat preservation box in the prior art. The heat preservation box suitable for the battery device comprises a box body and a box cover, and the box body and the box cover are connected in cooperation, wherein the box body is provided with a recessed cavity for containing the battery device. The heat preservation box has good heat preservation effect and improved strength.

Description

Technical Field

[0001] This invention relates to the field of insulated boxes, and more particularly to an insulated box suitable for battery devices and its installation method. Background Technology

[0002] The driving range of electric vehicles is one of the key factors affecting their overall performance, and the power battery pack is the energy source for these vehicles. Commonly used power battery packs include ternary lithium batteries and lithium iron phosphate batteries. The charging and discharging capacity and safety of lithium batteries are closely related to temperature. At high temperatures, batteries are at risk of thermal runaway, requiring cooling measures; at low temperatures, the charging and discharging capacity of batteries drops significantly, necessitating heating measures.

[0003] In cold northern regions, low winter temperatures cause battery packs to continuously leak heat into the environment. To ensure normal charging and discharging, heating elements are typically used to heat the battery packs during use. The lower ambient temperature increases battery energy consumption, significantly reducing the driving range of electric vehicles and becoming a limiting factor for the widespread adoption of electric vehicles in cold northern regions.

[0004] Currently, for electric vehicles, insulation devices are typically used to keep the batteries warm. These devices are usually made of plastic shells, which cannot withstand the long-term bumps and impacts of electric vehicles in terms of compressive strength and shock resistance. As a result, the shells of the insulation devices are often damaged, leading to battery leakage. Summary of the Invention

[0005] Based on the above analysis, the present invention aims to provide a battery device, an insulation box, a method for installing the battery device and the insulation box respectively, and a battery temperature control method, so as to solve the problems of poor strength and poor insulation performance of the insulation box in the prior art.

[0006] The objective of this invention is mainly achieved through the following technical solutions:

[0007] An insulated box for battery devices includes a box body and a box lid, characterized in that the box body and the box lid are connected together, and the box body has a cavity for holding the battery device.

[0008] Furthermore, the box body includes an outer shell and an inner liner; a sandwich layer is provided between the outer wall of the inner liner and the inner wall of the outer shell.

[0009] Furthermore, a support frame is provided between the interlayers; the outer edge of the support frame is in contact with the outer wall of the inner liner and the outer wall of the outer shell.

[0010] Furthermore, the support frame is provided with multiple cross-shaped through holes.

[0011] Furthermore, the upper side of the outer shell of the box is provided with an outwardly extending plate-shaped outer edge, and the upper side of the inner liner of the box is provided with an outwardly extending plate-shaped inner liner outer edge.

[0012] Furthermore, the side wall of the outer shell of the box is provided with a box vacuum extraction port, which communicates with the interlayer.

[0013] Furthermore, the lid includes an upper lid plate and a lower lid plate. The lower surface of the upper lid plate is provided with a first rectangular concave cavity, and the upper surface of the lower lid plate is provided with a second rectangular concave cavity. The first rectangular concave cavity and the second rectangular concave cavity form a closed cavity.

[0014] Furthermore, a vacuum extraction port is provided at one end of the upper plate of the box cover, and the vacuum extraction port communicates with the closed cavity.

[0015] Furthermore, one end of the upper and lower plates of the cover is provided with an antifreeze outlet hole and a phase change material outlet hole, and the other end is provided with an antifreeze inlet hole and a phase change material inlet hole.

[0016] Furthermore, a method for installing an insulated box suitable for battery devices includes the following steps:

[0017] Step S1: Assemble the lid;

[0018] Step S2: Assemble the boxes;

[0019] Step S3: Place the battery pack into the insulation box and close the insulation box. Installation is complete.

[0020] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0021] (1) An insulated box for holding the battery pack according to the present invention includes a box body and a box cover, which can be connected together. The box body and the box cover are provided with a vacuum interlayer inside, so that the interlayer can form a hollow vacuum structure by evacuation, thereby realizing the insulation effect of the battery device in three dimensions.

[0022] (2) The insulated box of the present invention has an integrated support frame in the interlayer of the box body. The support frame is preferably made of fiberglass. Fiberglass has high strength and hardness, which can play a good supporting role between the interlayers, so that the entire insulated box body can achieve the function of heat preservation while also having extremely high strength and impact resistance. At the same time, the low thermal conductivity of fiberglass makes it difficult for the entire insulated box to conduct heat when placed between the outer shell and the inner liner, thus reducing the heat leakage rate of the entire insulated box body.

[0023] (3) The present invention further includes multiple cross-shaped through holes on the support frame. Each cross-shaped through hole comprises four cylindrical holes that are interconnected in a cross shape, and the ends of the four cylindrical holes extend to the four sides of the support rod. The plane containing the axes of the four cylindrical holes is perpendicular to the axis of the support rod. This design creates a connected cavity between the outer shell and the inner liner of the box, thereby enabling more complete vacuuming between the layers and achieving a better vacuuming effect.

[0024] (4) In this invention, a pair of opposing cylindrical holes of the cross-shaped through hole on the support frame fits into the outer wall of the inner liner and the inner wall of the outer shell of the box, while another pair of cylindrical holes perpendicular to it communicates with the interlayer. This allows the box to be vacuumed through the pair of cylindrical holes communicating with the interlayer when vacuuming, so that the edges of the other pair of cylindrical holes perpendicular to it can fit tightly into the outer wall of the inner liner and the inner wall of the outer shell of the box. This allows the support frame to adhere to the outer wall of the inner liner and the inner wall of the outer shell of the box due to the vacuum effect without shaking, thus increasing the stability of the support frame and the box.

[0025] (5) This invention provides vacuum ports on all vacuuming devices, allowing each device to perform vacuuming operations as needed, making operation simple and the vacuuming range flexible. Preferably, when the vacuum degree reaches 10... -3 When high vacuum insulation is achieved, the structure is simple and can achieve good insulation effect according to the needs.

[0026] (6) The present invention provides transverse retainers and longitudinal retainers between and around the battery packs. The cooperation between the two makes the entire battery pack structurally stable and maintain its stability after the transverse retainers and longitudinal retainers are inserted.

[0027] (7) The longitudinal and transverse retainers of the present invention are preferably made of a high thermal conductivity and impact resistant polymer material with a certain strength, so that they have a certain strength and excellent thermal conductivity, and can maintain the stability of the entire battery pack structure even if the vehicle is subjected to a strong impact.

[0028] (8) The retainer of the present invention is preferably a high thermal conductivity silicone sheet, which is soft and has good toughness, so as to achieve effective contact with the battery cell and reduce the uneven heat transfer caused by the unevenness of the upper and lower sides of the battery cell. This design can not only fix and stabilize the battery pack and the overall shape, but also play a role in heat exchange and transfer between battery cells. It also has impact resistance to resist the vibration during normal vehicle use, and to a certain extent resists strong vehicle impacts, preventing short circuits caused by changes in battery arrangement that could lead to explosions.

[0029] (9) The double-layer combined flat tube of the present invention has a double-layer structure. The inner layer is used to fill antifreeze. The antifreeze can achieve temperature change by cooling or heating by an external temperature controller. The annular gap between the inner and outer layers is filled with phase change material. The temperature change of the antifreeze is transferred to the phase change material in the annular gap through the thermal conductivity of the inner rigid flat tube. The temperature regulation and temperature control of the battery are achieved through the phase change of the phase change material and temperature conduction.

[0030] (10) The outer layer of the double-layer composite flat tube in this invention is a soft flat tube made of a flexible thermally conductive material, preferably thermally conductive silicone. The most prominent feature of the outer soft flat tube is its flexibility and elasticity. When the phase change material undergoes a phase change in the annular gap and its volume changes, the outer soft flat tube will deform accordingly with the change in the volume of the phase change material in the annular gap.

[0031] (11) Due to the volume change during the phase change process of the phase change material, the deformation direction of the outer soft flat tube encapsulating the phase change material extends towards the space where the outer soft flat tube is not filled. That is, when the outer soft flat tube deforms, its deformation direction naturally extends into the gaps between the battery packs and between the battery cells. This ensures that the outer wall of the outer soft flat tube not only fits against the sidewalls of the battery cells but also against the top and bottom edges of the battery cells. This design achieves three-dimensional heat transfer to the battery cells from the phase change material on six sides, comprehensively and multi-directionally transferring heat to the battery cells, making the battery more uniformly heated and the heat conduction rate faster.

[0032] (12) When the outer soft flat tube of the present invention deforms, its outer wall will simultaneously achieve extreme extension in both the lateral and longitudinal directions. After extending to a certain extent, it will contact the longitudinal retainer and the lateral retainer around the battery pack, so that the outer soft flat tube is connected to all the retainers of the battery pack, realizing a closed loop network of interconnected grids of the entire battery pack. This enables comprehensive, multi-directional, and three-dimensional heat transfer to the entire battery pack, making the battery pack more uniformly heated and the heat conduction rate faster. Therefore, it reduces the power consumption of the battery pack, extends the single-use time of the battery pack, and avoids the situation where the battery pack explodes due to uneven heating.

[0033] (13) The outer layer of the double-layer composite flat tube of the present invention is a soft flat tube, and the inner layer is a hard flat tube. This double-layer composite flat tube maintains the strength of the entire composite flat tube through the inner hard flat tube, ensuring a certain degree of support between the battery packs. At the same time, the inner hard flat tube ensures the flexibility, elasticity, and compressive strength of the composite flat tube, which can resist impact forces to a certain extent. Therefore, this double-layer composite flat tube combining soft and hard materials achieves the dual functions of strength and flexibility, enabling the entire battery pack to maintain a certain strength while resisting impact forces, thus achieving a buffering and shock absorption effect for the entire battery pack.

[0034] (14) The double-layer combined flat tube of the present invention can also be designed with both layers made of flexible thermal conductive material, so that it can be bent in any direction and any shape in the tube channel when it is installed and arranged. It is convenient, quick and easy to operate and easy to process. At the same time, it can improve the fit of the battery cells in the double-layer combined flat tube, making the heat conduction effect of the whole device better. Since both the inner and outer layers of the double-layer combined flat tube are made of flexible thermal conductive material, the impact resistance and pressure resistance of the whole battery pack will be better, and the buffering and shock absorption effect of the whole battery pack will be achieved.

[0035] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages will become apparent from the description or may be learned by practicing the invention. Attached Figure Description

[0036] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0037] Figure 1 This is a three-dimensional schematic diagram of the battery device of the present invention;

[0038] Figure 2 For the present invention Figure 1 Sectional view of section AA;

[0039] Figure 3 This is a longitudinal sectional view showing the morphological changes of the double-layer combined flat tube under temperature changes according to the present invention.

[0040] Figure 4 For the present invention Figure 3 A magnified view of part A in the middle;

[0041] Figure 5 This is a three-dimensional schematic diagram of the insulated box used to hold the battery device in this invention;

[0042] Figure 6 This is an exploded view of the insulated box in this invention;

[0043] Figure 7 For the present invention Figure 6 A partial enlarged view of section B of the insulation box;

[0044] Figure 8 This is an exploded view of the lid of the insulated box in this invention.

[0045] Figure label:

[0046] 1: Battery pack; 1-1: Longitudinal battery pack; 1-2: Lateral battery pack; 1-3: Individual battery cell; 1-4: Longitudinal retainer; 1-5: Lateral retainer; 1-6: Gap; 1-7: Antifreeze outlet; 1-8: Antifreeze inlet; 1-9: Phase change material outlet; 1-10: Phase change material inlet;

[0047] 2: Double-layer composite flat tube; 2-1: Inner flat tube; 2-2: Outer flat tube; 2-3: Annular gap; 2-4: Flow channel;

[0048] 3: Insulated box; 3-1: Box body; 3-1-1: Outer shell of the box; 3-1-2: Inner liner of the box; 3-1-3: Support frame; 3-1-4: Cross-shaped through hole; 3-1-5: Outer edge of the outer shell; 3-1-6: Outer edge of the inner liner; 3-1-7: Vacuum extraction port of the box; 3-1-8: Sealing ring of the box;

[0049] 3-2: Box cover; 3-2-1: Upper plate of box cover; 3-2-2: Lower plate of box cover; 3-2-3: Vacuum extraction port of box cover; 3-2-4: Sealing plug; 3-2-5: Electrical connector; 3-2-7: Antifreeze outlet through hole; 3-2-8: Antifreeze inlet through hole; 3-2-9: Phase change material outlet through hole; 3-2-10: Phase change material inlet through hole. Detailed Implementation

[0050] The following detailed description of an insulated box suitable for battery devices, with reference to specific embodiments, is provided. These embodiments are for comparative and illustrative purposes only, and the present invention is not limited to these embodiments.

[0051] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the term "connected" should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0052] Throughout the text, the terms “top,” “bottom,” “above,” “below,” and “on top” refer to the relative positions of components of the device, such as the relative positions of the top and bottom substrates within the device. It is understood that the device is multifunctional and independent of its spatial orientation.

[0053] The working surface of this invention can typically be a plane or a curved surface, and can be inclined or horizontal. For ease of explanation, the embodiments of this invention are placed on a horizontal surface and used on a horizontal surface, thereby defining "height" and "vertical".

[0054] Example 1

[0055] One specific embodiment of the present invention discloses an insulated box for holding battery devices, such as... Figure 5 As shown, the insulation box 3 includes a box body 3-1 and a box cover 3-2. The box cover 3-2 is a rectangular plate structure, consistent with the upper shape of the box body 3-1, and the two can be connected to fit together. The box body 3-1 includes an outer shell 3-1-1 and an inner liner 3-1-2, which are fitted together. The length of the outer shell 3-1-1 in all three directions (length, width, and height) is greater than the length, width, and height of the inner liner 3-1-2, allowing the inner liner 3-1-2 to be placed inside the outer shell 3-1-1. A gap is left between the outer wall of the inner liner 3-1-2 and the inner wall of the outer shell 3-1-1, allowing the gap to form a hollow vacuum structure by vacuuming, thus achieving the insulation effect of the entire insulation box 3 on the battery.

[0056] Furthermore, such as Figure 6 As shown, an integrated support frame 3-1-3 is provided between the layers. The support frame 3-1-3 is integrally formed by connecting multiple support rods perpendicularly to each other, so that its spatial shape matches the shape of the layers. The outer edge of the support frame 3-1-3 is in close contact with the outer wall of the inner liner 3-1-2 and the outer wall of the outer shell 3-1-1. The overall structure of the support frame 3-1-3 can strengthen the internal battery pack 1.

[0057] Furthermore, such as Figure 7 As shown, the support frame 3-1-3 is provided with a plurality of cross-shaped through holes 3-1-4. Each cross-shaped through hole 3-1-4 includes four cylindrical holes, which are interconnected in a cross shape. The ends of the four cylindrical holes extend to the four sides of the support rod. The plane containing the axis of the four cylindrical holes is perpendicular to the axis of the support rod, that is, the cross-shaped through holes 3-1-4 are set perpendicular to the axis of the support rod.

[0058] Furthermore, a pair of opposing cylindrical holes in the cross-shaped through-hole 3-1-4 fits against the outer wall of the inner liner 3-1-2 and the inner wall of the outer shell 3-1-1, while another pair of cylindrical holes perpendicular to it communicates with the interlayer. This allows the box 3-1 to be evacuated through the pair of cylindrical holes communicating with the interlayer during vacuuming, and the edges of the other pair of cylindrical holes perpendicular to it can fit tightly against the outer wall of the inner liner 3-1-2 and the inner wall of the outer shell 3-1-1. Consequently, the support frame 3-1-3 can adhere to the outer wall of the inner liner 3-1-2 and the inner wall of the outer shell 3-1-1 due to the vacuum effect without shaking, thus increasing the stability of the support frame 3-1-3 and the box 3-1.

[0059] Preferably, the support frame 3-1-3 is made of fiberglass. Fiberglass has high strength and hardness, providing excellent support between the layers, allowing the entire insulation box 3-1 to achieve insulation while also possessing high strength and impact resistance. Simultaneously, the low thermal conductivity of fiberglass, when placed between the outer shell 3-1-1 and the inner liner 3-1-2, hinders energy conduction within the insulation box, reducing the overall energy transfer rate of the insulation box 3-1.

[0060] Furthermore, the upper side of the outer shell 3-1-1 of the box is provided with an outwardly extending plate-shaped outer edge 3-1-5, and the upper side of the inner liner 3-1-2 of the box is also provided with an outwardly extending plate-shaped inner liner outer edge 3-1-6. After they are inserted into each other, the outer edges of the two are aligned with each other.

[0061] Specifically, the outer edge 3-1-5 of the outer shell and the outer edge 3-1-6 of the inner liner are provided with outer edge through holes. The outer edges of the outer shell 3-1 and the inner liner 3-1-2 of the box are connected and pressed together by bolts passing through the outer edge through holes to achieve a sealing effect. This method is simple and feasible, with low production cost, while maintaining a high degree of vacuum.

[0062] Furthermore, the side wall of the outer casing 3-1-1 is provided with a vacuum extraction port 3-1-7. A ball valve is installed inside the vacuum extraction port 3-1-7. The vacuum extraction port 3-1-7 communicates with the interlayer, allowing the interlayer to be evacuated through the vacuum extraction port 3-1-7. During evacuation, the ball valve is opened, and after reaching the set vacuum level, the ball valve is closed. When the vacuum level reaches 10... -3 When high vacuum insulation is achieved, the structure is simple and can achieve good heat insulation effect.

[0063] Furthermore, grooves are provided on the lower side of the outer edge 3-1-5 of the outer shell and the upper side of the outer edge 3-1-6 of the inner liner, and a box sealing ring 3-1-8 is provided in the grooves to achieve a better sealing effect.

[0064] Furthermore, such as Figure 8 As shown, the lid 3-2 includes an upper lid plate 3-2-1 and a lower lid plate 3-2-2. The upper lid plate 3-2-1 and the lower lid plate 3-2-2 have the same shape. The lower surface of the upper lid plate 3-2-1 is provided with a first rectangular concave cavity, and the outer edge of the first rectangular concave cavity is close to the outer edge of the upper lid plate 3-2-1. The upper surface of the lower lid plate 3-2-2 is provided with a second rectangular concave cavity corresponding to the size of the first rectangular concave cavity. That is, the outer edge of the second rectangular concave cavity is also close to the outer edge of the lower lid plate 3-2-2. This allows the first and second rectangular concave cavities to form a closed cavity after the upper lid plate 3-2-1 and the lower lid plate 3-2-2 are closed, which can be used to create a hollow vacuum structure by evacuation.

[0065] Furthermore, grooves are provided on the outer edges of the first rectangular concave cavity and the second rectangular concave cavity. A top cover sealing ring is provided in the groove on the outer edge of the first rectangular concave cavity, and the top cover sealing ring is engaged with the groove on the outer edge of the second rectangular concave cavity.

[0066] Furthermore, the outer edges of the upper cover plate 3-2-1 and the lower cover plate 3-2-2 are provided with corresponding screw through holes. The upper cover plate 3-2-1 and the lower cover plate 3-2-2 are connected and pressed together by screws passing through the screw through holes to achieve a sealing effect. This method is simple and feasible, with low production cost, while maintaining a high vacuum degree.

[0067] Furthermore, a vacuum extraction port 3-2-3 is provided at one end of the upper plate 3-2-1 of the lid. A ball valve is installed inside the vacuum extraction port 3-2-3. The vacuum extraction port 3-2-3 communicates with the closed cavity, allowing the closed cavity to be evacuated through the vacuum extraction port 3-2-3. During evacuation, the ball valve is opened, and after reaching the set vacuum level, the ball valve is closed. When the vacuum level reaches 10... -3 When high vacuum insulation is achieved, the structure is simple and can achieve good heat insulation effect.

[0068] Furthermore, one corner of the upper cover plate 3-2-1 and the lower cover plate 3-2-2 is provided with an antifreeze outlet through hole 3-2-7 and a phase change material outlet through hole 3-2-9, and the other corner on the same side is provided with an antifreeze inlet through hole 3-2-8 and a phase change material inlet through hole 3-2-10.

[0069] Specifically, the antifreeze outlet through hole 3-2-7 is connected to the antifreeze outlet 1-7, and the phase change material outlet through hole 3-2-9 is connected to the phase change material outlet 1-9; the antifreeze inlet through hole 3-2-8 is connected to the antifreeze inlet 1-8, and the phase change material inlet through hole 3-2-10 is connected to the phase change material inlet 1-10.

[0070] Specifically, the four inlet and outlet through holes are all located between the closed cavity and the screw through hole, and each of the four inlet and outlet through holes is provided with a sealing plug 3-2-4 to achieve the function of sealing the four inlets and outlets and isolating them from the outside world.

[0071] Furthermore, an electrical connector 3-2-5 is provided on one side of the upper surface of the box cover 3-2. The electrical connector is connected to an external temperature control unit to realize temperature control of the battery pack inside the insulated box.

[0072] Example 2

[0073] A battery device contained within the insulated box of Embodiment 1 above, such as Figure 1 As shown, it includes a battery pack 1 and a battery temperature control device. The battery temperature control device is used to control the temperature of the battery pack 1. The battery pack 1 is composed of multiple identical vertical battery rows 1-1 arranged side by side, which are longitudinally parallel and aligned with each other.

[0074] A pipe channel is provided between two adjacent longitudinal battery packs 1-1, and a battery temperature control device is provided between the pipe channels.

[0075] Furthermore, the battery temperature control device includes a double-layer combined flat tube 2, a temperature sensor, and an external temperature control device. The double-layer combined flat tube 2 is wound in an S-shape in two adjacent pipe channels, so that the outer wall of the double-layer combined flat tube 2 is in contact with the outer wall of the longitudinal battery pack 1-1, thereby allowing the temperature of the entire battery pack 1 to be regulated by the temperature change of the double-layer combined flat tube 2.

[0076] Preferably, the battery device is used in automobiles, electric bicycles, or other electric vehicles.

[0077] Furthermore, the temperature sensor is used to measure the temperature of the battery pack 1; the external temperature control device is used to heat or cool the double-layer combined flat tube 2.

[0078] Furthermore, the longitudinal battery pack 1-1 is composed of multiple identical transverse battery packs 1-2 stacked longitudinally side by side, with the multiple transverse battery packs 1-2 arranged horizontally parallel and aligned with each other. Each transverse battery pack 1-2 is composed of multiple identical battery cells 1-3, arranged side by side and aligned, meaning the outer wall of the double-layer combined flat tube 2 is in contact with the side walls of each battery cell 1-3. Furthermore, transverse retainers 1-4 are provided between adjacent sets of transverse battery packs 1-2 in the same column of longitudinal battery packs 1-1, and at the top and bottom of the same column of longitudinal battery packs 1-1. The transverse retainers 1-4 are elongated and contact the bottom and top of each battery cell 1-3.

[0079] Furthermore, such as Figure 2 As shown, the double-layer combined flat tube 2 includes a flat portion and a bent portion. The flat portion is parallel to the transverse side of the longitudinal battery pack 1-1. The bent portion is parallel to the width side of the longitudinal battery pack 1-1, and its longitudinal direction is parallel to the longitudinal side of the longitudinal battery pack 1-1. That is, the double-layer combined flat tube 2 is wrapped around the side of each battery cell 1-3, so that the double-layer combined flat tube 2 is in contact with the outer side wall of the battery cell 1-3.

[0080] Furthermore, such as Figure 3 As shown, the width of the transverse retainer 1-4 is smaller than the width of the battery cell 1-3. Therefore, after two adjacent transverse battery packs 1-2 come into contact with the transverse retainer 1-4, gaps 1-6 are formed on both sides of the transverse retainer 1-4 and between the upper and lower transverse battery packs 1-2.

[0081] Furthermore, the top and bottom of the battery pack 1 are provided with lateral retainers 1-5, and the lateral retainers 1-5 are provided with recesses that match the transverse retainers 1-4. The recesses can be connected with the transverse retainers 1-4, so that after the lateral retainers 1-5 and the transverse retainers 1-4 are inserted, the overall battery pack structure can be stabilized and its stability can be maintained.

[0082] Furthermore, the transverse retainer 1-4 and the lateral retainer 1-5 are preferably made of a high-thermal-conductivity and impact-resistant polymer material with a certain strength, so that they have a certain strength and excellent thermal conductivity, and can still maintain the stability of the entire battery pack structure even if the electric vehicle is subjected to a strong impact.

[0083] Specifically, the transverse retainer 1-4 and the lateral retainer 1-5 are preferably high thermal conductivity silicone sheets, which are soft yet have good toughness, enabling effective contact with the battery cells 1-3 and reducing uneven heat transfer caused by unevenness on the upper and lower sides of the battery cells 1-3. Optionally, the upper surface of the transverse retainer 1-4 is provided with a cavity matching the battery cells 1-3. The cavity can position the battery cells 1-3 and also reduce vibration and increase the heat exchange area. The combination of the transverse retainer 1-4 and the lateral retainer 1-5, along with their materials, can not only fix and stabilize the longitudinal battery packs 1-1 and the overall shape, but also facilitate heat exchange and transfer between the battery cells. Furthermore, they have impact resistance to withstand vibrations during normal vehicle use and, to a certain extent, resist strong vehicle impacts, preventing short circuits and explosions caused by changes in battery arrangement.

[0084] Furthermore, such as Figure 4 As shown, the double-layer composite flat tube 2 has a double-layer structure, including an inner flat tube 2-1 and an outer flat tube 2-2. An annular gap 2-3 is provided between the inner flat tube 2-1 and the outer flat tube 2-2. The annular gap 2-3 is used to fill phase change material, that is, the space between the inner flat tube 2-1 and the outer flat tube 2-2 is the storage space for phase change material. Both the inner flat tube 2-1 and the outer flat tube 2-2 are made of thermally conductive materials.

[0085] Specifically, the phase change material can undergo a solid-liquid transition at its melting point; that is, the transition from solid to liquid is an endothermic process, and the transition from liquid to solid is an exothermic process. Furthermore, the volume of the phase change material will change during the solid-liquid phase transition.

[0086] Specifically, the inner flat tube 2-1 is an inner rigid flat tube with a flow channel 2-4 inside for holding antifreeze. The antifreeze can achieve temperature change by cooling or heating through an external temperature control device. The temperature change is then transferred to the phase change material in the annular gap 2-3 through the thermal conductivity of the inner rigid flat tube. The phase change and temperature conduction of the phase change material then achieve the temperature regulation and control of the battery.

[0087] Specifically, the antifreeze can be heated by an external temperature control device to raise its temperature; simultaneously, the antifreeze can also be cooled by the same external temperature control device to lower its temperature. Preferably, the external temperature control device is a temperature controller.

[0088] Furthermore, the outer flat tube 2-2 is a soft outer flat tube made of a flexible thermally conductive material, preferably thermally conductive silicone. The most significant characteristic of the outer soft flat tube is its flexibility and elasticity. When the phase change material undergoes a phase change and its volume changes within the annular gap 2-3, the outer soft flat tube will deform accordingly with the volume change of the phase change material within the annular gap 2-3.

[0089] Specifically, when the phase change material in the annular gaps 2-3 undergoes a solid-liquid phase change, the outer soft flat tube deforms. The deformation extends towards the unfilled space of the double-layer combined flat tube 2. Since the outer wall of the outer soft flat tube is tightly fitted to the side walls of each battery cell 1-3, with no gaps between the two walls, the deformation direction naturally extends towards the gaps 1-6 between the transverse battery rows 1-2, or more specifically, towards the gaps 1-6 between the battery cells 1-3, causing the outer wall of the outer soft flat tube to fit against the top and bottom edges of the battery cells. In other words, the outer wall of the outer soft flat tube can wrap around the side walls of the battery cells while also wrapping around the top and bottom of the battery cells 1-3, thus achieving three-dimensional, six-sided heat transfer from the phase change material to the battery cells 1-3, comprehensively and multi-directionally transferring energy to the battery cells, resulting in more uniform and faster energy transfer.

[0090] Furthermore, when the outer wall of the outer soft flat tube extends to a certain extent, it will come into contact with the transverse retainer 1-4, that is, the outer soft flat tube and the transverse retainer 1-4 form a closed loop for energy transfer around each battery cell 1-3.

[0091] Furthermore, the outer wall of the outer soft flat tube extends longitudinally. After extending to a certain extent, it contacts the transverse retainer 1-4 and the lateral retainer 1-5 at the top and bottom of the longitudinal battery pack 1-1, realizing a closed loop between the entire longitudinal battery pack 1-1. Finally, the closed loop, through the lateral retainer 1-5, realizes a grid-like interconnected closed loop network of the entire battery pack 1. The closed loop network achieves comprehensive, multi-directional, three-dimensional heat transfer for the entire battery pack 1, making the energy transfer of the battery pack 1 more uniform and the energy conduction rate faster. Therefore, it increases the stability of the battery pack 1, reduces the impact of temperature on the energy consumption of the battery pack, extends the service life of the battery pack 1 on a single charge, increases the driving range of the electric vehicle on a single charge, and avoids the electric vehicle's battery from exploding due to uneven heating or rapidly losing power in cold winter conditions.

[0092] Specifically, the combination of the outer soft flat tube and the inner hard flat tube enables the double-layer combined flat tube 2 to maintain the strength of the entire double-layer combined flat tube 2 through the inner hard flat tube, so that it can guarantee a certain degree of support between the longitudinal battery packs 1-1. At the same time, the inner hard flat tube ensures the flexibility, elasticity and compressive strength of the double-layer combined flat tube 2, which can resist impact to a certain extent. Therefore, the double-layer combined flat tube 2, which combines softness and hardness, realizes the dual functions of strength and flexibility, so that the entire battery pack can maintain its strength and resist impact, thus achieving the buffering and shock absorption effect of the entire battery pack.

[0093] Furthermore, one end of the double-layer combined flat tube 2 is provided with an antifreeze outlet 1-7, which is connected to the inner flat tube 2-1. At the same end, a phase change material outlet 1-9 is also provided, which is connected to the annular gap 2-3. The other end of the double-layer combined flat tube 2 is provided with an antifreeze inlet 1-8, which is connected to the inner flat tube 2-1. At the same end, a phase change material inlet 1-10 is also provided, which is connected to the annular gap 2-3.

[0094] Furthermore, the battery pack 1 is provided with a power connection cable, and the housing 3 is provided with a power connection cable connector. The battery pack 1 is connected to the electric vehicle through the power connection cable connector, thereby charging the battery pack 1 and discharging the electric vehicle from the battery pack 1.

[0095] Example 3

[0096] Optionally, the double-layer combined flat tube 2 has a double-layer structure, including an inner flat tube 2-1 and an outer flat tube 2-2, both of which are made of flexible thermally conductive material. The flexibility of the double-layer combined flat tube 2 allows for bending in any direction and shape within the tube channel during installation, making installation convenient, quick, easy, and easy to process. It also improves the fit between the double-layer combined flat tube 2 and the battery cells 1-3 and the longitudinal battery array 1-1, resulting in better heat conduction of the entire device. Since both double-layer combined flat tubes 2 are made of flexible thermally conductive material, the impact and pressure resistance of the entire battery pack is better, achieving a buffering and shock absorption effect.

[0097] Example 4

[0098] An installation method for the insulated box based on Embodiments 1-3, characterized by comprising the following steps:

[0099] Step S1: Assemble the lid (3-2):

[0100] The upper cover plate (3-2-1) and the lower cover plate (3-2-2) are aligned and connected to each other, so that the first rectangular concave cavity and the second rectangular concave cavity are connected to each other to form a closed cavity. Then, screws are passed through the screw holes to connect and press the two together to achieve a sealing effect.

[0101] Next, the closed cavity is evacuated through the vacuum port (3-2-3) of the box cover to complete the assembly of the box cover (3-2).

[0102] Step S2: Assemble the box (3-1):

[0103] The support frame 3-1-3 is placed inside the outer shell 3-1-1, and then the inner liner 3-1-2 is fitted into the outer shell 3-1-1, such that the outer edge of the support frame 3-1-3 fits against the outer wall of the inner liner 3-1-2 and the outer wall of the outer shell 3-1-1, and simultaneously, the pair of opposing cylindrical holes of the cross-shaped through hole 3-1-4 fits against the outer walls of the inner liner 3-1-2 and the outer wall of the outer shell 3-1-1. Next, the outer edge through holes on the outer edge of the outer shell 3-1-5 and the outer edge of the inner liner 3-1-6 are connected and tightened by bolts.

[0104] Next, a vacuuming operation is performed through the vacuum extraction port 3-1-7 of the box body, so that when the box body 3-1 is vacuumed, it can be vacuumed through a pair of cylindrical holes communicating with the interlayer, so that the edge of the other pair of cylindrical holes perpendicular to it can be tightly fitted with the outer wall of the inner liner 3-1-2 and the outer wall of the outer shell 3-1-1.

[0105] Step S3: Place the battery pack into the insulation box (3) and close the insulation box. Installation complete.

[0106] The battery device of Embodiment 2 or Embodiment 3 is placed into the insulation box (3). The installation method of the battery device includes the following steps:

[0107] Step S11: Arrange battery cells 1-3 in an array to form battery pack 1:

[0108] Battery cells 1-3 are arranged side by side to form a horizontal battery row 1-2. Multiple horizontal battery rows 1-2 are stacked to form a vertical battery row 1-1. The vertical battery rows 1-1 are then arranged side by side to form a battery pack 1, and a pipe channel is left between adjacent columns of vertical battery rows 1-1.

[0109] Step S22: Install the retainer for battery pack 1:

[0110] Place a transverse retainer 1-4 at the top and bottom of each transverse battery pack 1-2, and then place a lateral retainer 1-5 at the bottom of the insulation box. Then place the assembled battery pack 1 inside the insulation box, so that the lateral retainer 1-5 and the transverse retainer 1-4 can be inserted into each other to form a stabilizing and fixing effect on the entire battery pack 1.

[0111] The width of the transverse retainer 1-4 is smaller than the width of the battery cell 1-3. Therefore, after the transverse retainer 1-4 is installed between the transverse battery packs 1-2, a gap 1-6 is formed on both sides of the transverse retainer 1-4 between the transverse battery packs 1-2.

[0112] Step S33: Install the battery temperature control device:

[0113] The unfilled double-layer combined flat tube 2 is wound in an S-shape into the pipe channel, with the flat portion of the double-layer combined flat tube 2 parallel to the side of the longitudinal battery pack 1-1. Then, the bent portion of the double-layer combined flat tube 2 is wrapped around the width side of the longitudinal battery pack 1-1, so that the longitudinal direction of the bent portion is parallel to the longitudinal side of the longitudinal battery pack 1-1. Then, the flat portion of the double-layer combined flat tube 2 is made parallel to the side of the longitudinal battery pack 1-1. This process is repeated to fill the pipe channel with the double-layer combined flat tube 2, so that the outer wall of the double-layer combined flat tube 2 is in contact with the outer wall of the longitudinal battery pack 1-1.

[0114] Connect the antifreeze outlet through hole 3-2-7 to the antifreeze outlet 1-7, and connect the phase change material outlet through hole 3-2-9 to the phase change material outlet 1-9; then connect the antifreeze inlet through hole 3-2-8 to the antifreeze inlet 1-8, and connect the phase change material inlet through hole 3-2-10 to the phase change material inlet 1-10.

[0115] Place another lateral retainer 1-5 on the top of the battery pack 1 with the double-layer combined flat tube 2 wound around it, and connect it with the transverse retainer 1-4 on the top of the battery pack 1. Then fasten the cover 3-2 and seal the antifreeze outlet through hole 3-2-7 and the phase change material outlet through hole 3-2-9 with sealing plugs.

[0116] Antifreeze is poured into the flow channel 2-4 through the antifreeze inlet hole 3-2-8, so that the inner flat tube 2-1 is filled with antifreeze. Then, the antifreeze inlet hole 3-2-8 is sealed with a sealing rubber plug.

[0117] Connect the temperature sensor to battery pack 1; connect the external temperature control device to the double-layer combined flat tube 2.

[0118] Step S44: Deform the double-layer composite flat tube 2

[0119] Double-layer composite flat tube 2 Deformation form 1:

[0120] The solid-liquid mixed phase change material is injected into the annular gap 2-3 through the phase change material inlet hole 3-2-10, so that the space between the inner flat tube 2-1 and the outer flat tube 2-2 is filled with phase change material, and then the phase change material inlet hole 3-2-10 is sealed with a sealing rubber plug.

[0121] When battery pack 1 is started, the temperature of battery pack 1 rises and dissipates heat. At this time, the phase change material in the annular void 2-3 changes from a solid-liquid mixed state to a liquid state. The overall volume of the phase change material in the annular void 2-3 increases, causing the outer flat tube 2-2 to deform.

[0122] The deformation of the outer wall of the outer flat tube 2-2 extends towards the unfilled space of the double-layer combined flat tube 2. Specifically, the outer flat tube 2-2 expands and extends into the gaps 1-6 and towards the top and bottom edges of the battery cells 1-3. This allows the double-layer combined flat tube 2 to contact the sidewalls, top, and bottom of the battery cells 1-3, achieving three-dimensional heat transfer on six sides. This comprehensive and multi-directional heat transfer to the battery cells results in more uniform battery energy distribution and faster energy conduction. Furthermore, the outer flat tube 2-2 deforms after the double-layer combined flat tube 2 is installed in the battery pack 1. This method makes the installation of the double-layer combined flat tube convenient and quick, saving manpower and costs.

[0123] Since the outer flat tube 2-2 is made of a flexible thermally conductive material, it has a certain degree of flexibility. Therefore, when the double-layer combined flat tube 2 is deformed, even if the phase change material is cooled and changes from liquid to solid, and the volume becomes smaller, the outer wall of the outer flat tube 2-2 will shrink to a certain extent. However, a part of it will still remain in the gap 1-6 to achieve heat conduction to the sides of the battery cell 1-3 as well as part of the top and bottom.

[0124] Double-layer composite flat tube 2 Deformation form two:

[0125] Liquid phase change material is injected into the annular gap 2-3 under high pressure through the phase change material inlet hole 3-2-10, filling the space between the inner flat tube 2-1 and the outer flat tube 2-2 with phase change material. Due to the high-pressure filling and the fact that the outer flat tube 2-2 is made of flexible thermally conductive material, the liquid phase change material causes the deformation of the outer wall of the outer flat tube 2-2 to extend towards the unfilled space of the double-layer combined flat tube 2 during the high-pressure filling process. That is, the outer flat tube 2-2 expands and extends into the gap 1-6 and towards the top and bottom edges of the battery cell 1-3, achieving contact between the double-layer combined flat tube 2 and the sidewalls, top, and bottom of the battery cell 1-3, realizing three-dimensional heat transfer on six sides. This comprehensive and multi-directional heat transfer to the battery cell results in more uniform battery energy and a faster energy conduction rate. In addition, the outer flat tube 2-2 deforms after the double-layer combined flat tube 2 is installed in the battery pack 1. This method makes the installation of the double-layer combined flat tube convenient and quick, saving manpower and costs.

[0126] After the battery temperature control device is completed, seal the phase change material inlet hole 3-2-10 with a sealing plug.

[0127] Example 5

[0128] A battery temperature control method for controlling the temperature of the battery devices in Examples 1-3 includes the following steps:

[0129] The phase change material has a melting point of T0. The temperature sensor measures the temperature of battery pack 1 as t1, and the ambient temperature as t2. Based on different operating modes, the operating modes can be divided into cooling mode M1, heat preservation mode M2, and heating mode M3. The lower and upper limits of the normal operating temperature of the battery are T1 and T2, respectively. Where T2 > T1 = T0.

[0130] Among them, cooling mode M1 cools the antifreeze, thereby cooling the battery pack 1; heat preservation mode M2 ​​uses the heat absorption or release properties of phase change materials to keep the battery pack 1 warm; heating mode M3 heats the battery pack 1 by self-heating the battery or heating the antifreeze.

[0131] When t2 > T2, the phase change material is in a liquid state, and the external environment transfers heat to battery pack 1, causing battery pack 1 to heat up. When the temperature of battery pack 1 t1 > T2, battery pack 1 exceeds the upper limit of the normal operating temperature of the battery and needs to be cooled. Cooling mode M1 is activated until T2 > t1 and then cooling stops.

[0132] When T2≥t2≥T1, the phase change material is in a solid-liquid mixed state and is under normal battery operating temperature conditions. When the temperature of battery pack 1 is T2≥t1≥T1, the heat preservation mode M2 ​​is activated. After battery pack 1 has been working for a certain period of time, the battery pack 1 generates heat, causing the temperature to rise. At this time, battery pack 1 transfers heat to the double-layer combined flat tube 2. The phase change material in the double-layer combined flat tube 2 absorbs the heat from battery pack 1, thereby cooling battery pack 1 so that the temperature t1 of battery pack 1 is T2≥t1≥T1.

[0133] When t2 < T1, the phase change material is solid, and battery pack 1 transfers heat to the external environment. At this time, the operating mode of battery pack 1 is heating mode M3. In the heating mode M3, there are two heating methods: one is battery self-heating, and the other is antifreeze heating.

[0134] Battery self-heating method:

[0135] When battery pack 1 is working, its temperature continuously increases. When the temperature of the battery pack reaches t1 = T0 = T1, the phase change material absorbs the heat emitted by battery pack 1 and changes from a solid state to a liquid state, maintaining the temperature stability of battery pack 1. When battery pack 1 briefly stops working, its temperature decreases. At this time, the phase change material releases heat and changes from a liquid state to a solid state, which is used to maintain the temperature stability of battery pack 1.

[0136] Antifreeze heating method:

[0137] When battery pack 1 is not working for a long time, that is, when the electric vehicle is not started for a long time, the phase change material in battery pack 1 is in a solid state. At this time, battery pack 1 can be heated by the antifreeze in the inner flat tube 2-1, so that the heat of the antifreeze is transferred to battery pack 1, making the temperature of battery pack t1 = T1, and keeping battery pack 1 in working mode.

[0138] Specifically, the phase change material undergoes a solid-liquid phase change within the temperature range of T1-T2, thereby achieving the functions of absorbing and releasing heat for battery pack 1. In other words, the phase change material absorbs and stores the heat generated by battery pack 1 during operation, thus enabling it to regulate the temperature of battery pack 1.

[0139] Furthermore, in winter when ambient temperatures are low, after a long period of parking, the initial temperature t1 of battery pack 1 is low. At this time, when battery pack 1 is started and enters its working mode, it generates heat, which the phase change material absorbs, resulting in only a slight temperature rise. When battery pack 1 is not in operation, it stops charging and discharging. Due to the energy stored in the phase change material and the excellent insulation effect of the vacuum-insulated enclosure, the battery pack can maintain a specified temperature range for a longer period of time, reducing the time and frequency of active heating by external temperature control devices, thus reducing energy consumption and increasing driving range.

[0140] Furthermore, the combination of phase change material and insulation box can make full use of the small temperature change of phase change material during heat absorption and release, maintain stable battery pack temperature, and effectively reduce the time and frequency of external temperature control devices to start heating and cooling.

[0141] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An insulated box suitable for battery devices, comprising a box body (3-1) and a box lid (3-2), characterized in that, The box body (3-1) and the box cover (3-2) are connected together. The box body (3-1) is provided with a cavity for holding the battery device. The box body (3-1) includes an outer shell (3-1-1) and an inner liner (3-1-2); a sandwich layer is provided between the outer wall of the inner liner (3-1-2) and the inner wall of the outer shell (3-1-1); a support frame (3-1-3) is provided between the sandwich layers; the outer edge of the support frame (3-1-3) is in contact with the outer wall of the inner liner (3-1-2) and the inner wall of the outer shell (3-1-1); a plurality of cross-shaped through holes (3-1-4) are provided on the support frame (3-1-3), each cross-shaped through hole (3-1-4) including four cylindrical holes, which are interconnected in a cross shape, and the ends of the four cylindrical holes extend to the four sides of the support rod; The battery device includes a battery pack (1) and a battery temperature control device. The battery pack (1) is composed of multiple identical vertical battery rows (1-1) arranged side by side. A pipe channel is left between two adjacent vertical battery rows (1-1). The vertical battery row (1-1) is composed of multiple identical horizontal battery rows (1-2) stacked side by side in the longitudinal direction. The horizontal battery row (1-2) is composed of multiple identical battery cells (1-3). The top and bottom of the battery pack (1) are provided with lateral retainers (1-5). Horizontal retainers (1-4) are provided between two adjacent horizontal battery rows (1-2) and at the top and bottom of the same vertical battery row (1-1). The width of the horizontal retainer (1-4) is smaller than the width of the battery cell (1-3). Gaps (1-6) are formed on both sides of the horizontal retainer (1-4) and between the upper and lower horizontal battery rows (1-2). The battery temperature control device includes a double-layer combined flat tube (2), which is wound in an S-shape in two adjacent pipe channels. The double-layer combined flat tube (2) has a double-layer structure, including an inner flat tube (2-1) and an outer flat tube (2-2). An annular gap (2-3) for filling phase change material is provided between the inner flat tube (2-1) and the outer flat tube (2-2). A flow channel (2-4) for holding antifreeze is provided in the inner flat tube (2-1).

2. The insulated box suitable for battery devices according to claim 1, characterized in that, The outer shell of the box (3-1-1) has an outwardly extending plate-shaped outer edge (3-1-5) on its upper side, and the inner liner of the box (3-1-2) has an outwardly extending plate-shaped inner liner outer edge (3-1-6) on its upper side.

3. The insulated box suitable for battery devices according to claim 2, characterized in that, The side wall of the outer shell (3-1-1) of the box is provided with a box vacuum extraction port (3-1-7), which communicates with the interlayer.

4. The insulated box suitable for battery devices according to claim 1, characterized in that, The box cover (3-2) includes an upper box cover plate (3-2-1) and a lower box cover plate (3-2-2). The lower surface of the upper box cover plate (3-2-1) is provided with a first rectangular concave cavity, and the upper surface of the lower box cover plate (3-2-2) is provided with a second rectangular concave cavity. The first rectangular concave cavity and the second rectangular concave cavity form a closed cavity.

5. A heat preservation box suitable for battery devices according to claim 4, characterized in that, One end of the upper plate (3-2-1) of the box cover is provided with a box cover vacuum port (3-2-3), and the box cover vacuum port (3-2-3) communicates with the closed cavity.

6. A heat preservation box suitable for battery devices according to claim 5, characterized in that, The upper plate (3-2-1) and lower plate (3-2-2) of the box cover are provided with an antifreeze outlet through hole (3-2-7) and a phase change material outlet through hole (3-2-9) on one side, and an antifreeze inlet through hole (3-2-8) and a phase change material inlet through hole (3-2-10) on the other side.

7. A method for installing an insulated box suitable for battery devices, characterized in that, The installation of an insulation box suitable for a battery device as described in any one of claims 1-6 includes the following steps: Step S1: Assemble the lid (3-2); Step S2: Assemble the box (3-1); Step S3: Place the battery device into the insulation box (3) and close the insulation box to complete the installation.

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