Cooling assembly, power battery, fast charging thermal management control method and vehicle

Abstract

The present application discloses a cooling assembly, a power battery, a fast charging thermal management control method and a vehicle, which solves the technical problem of low cooling effect of the cooling assembly of the power battery in the prior art. The cooling assembly includes a first liquid cooling part and a second liquid cooling part. The first liquid cooling part is arranged on the first side of the battery cell assembly to cool the upper or lower part of the battery cell assembly. The second liquid cooling part is arranged between adjacent battery cells of the battery cell assembly, and the plane where the second liquid cooling part is located is arranged at an angle to the plane where the first liquid cooling part is located. A three-dimensional cooling structure is formed by the first liquid cooling part and the second liquid cooling part. The second liquid cooling part is arranged between adjacent battery cells and can be in thermal contact with the large surface of the battery cell. In the super fast charging scenario, it can effectively bring out the heat generated in the middle of the battery cell, meeting the thermal management requirements of 4C super fast charging.

Description

Technical Field

[0001] The present application belongs to the technical field of cooling devices, and specifically relates to a cooling assembly, a power battery, a fast charging thermal management control method, and a vehicle. Background Art

[0002] As vehicles evolve, electric vehicles are becoming increasingly popular. As the primary driving force of electric vehicles, the performance of power batteries impacts the overall performance of the vehicle. As power battery performance improves, they are moving toward higher-rate, higher-current charging.

[0003] Currently, the charge rate of fast-charging batteries is around 2C. Cell cooling is primarily single-sided, particularly for prismatic cells, which typically cool from the bottom because their tabs face upward and copper bars are located between them. However, at higher charging rates, heat generation increases exponentially, and traditional bottom-side cooling is no longer sufficient. For this reason, many vehicles on the market utilize dual-sided cooling for their power batteries, with liquid cooling components located above and below the cell assembly.

[0004] However, to meet customer demands for fast charging, extended service life, and increased mileage on a full charge, higher requirements are being placed on the battery pack's operating temperature range and the temperature differential between cells. This has led to increased demands for battery pack temperature control design. While ensuring mechanical strength and meeting various mechanical properties, improved cooling efficiency is crucial to achieve ultra-fast charging of the battery pack.

[0005] In summary, the cooling effect of existing power battery cooling components is limited and it is difficult to meet the heat dissipation requirements of super-fast charging. Summary of the Invention

[0006] In order to solve the technical problem that the cooling effect of the cooling assembly of the current power battery is low, the present application provides a cooling assembly, a power battery, a fast charging thermal management control method and a vehicle.

[0007] In a first aspect of the present application, a cooling assembly is provided for cooling a cell assembly of a power battery, comprising:

[0008] a first liquid cooling element, configured to be disposed on a first side surface of the battery cell assembly;

[0009] The second liquid cooling element is used to be arranged between adjacent battery cells of the battery cell assembly. The second liquid cooling element is connected to the first liquid cooling element, and the plane where the second liquid cooling element is located is arranged at an angle to the plane where the first liquid cooling element is located.

[0010] In some embodiments, the first liquid cooling element includes a first liquid cooling plate; the second liquid cooling element includes a plurality of second liquid cooling plates and a first distribution pipe for connecting the plurality of second liquid cooling plates, and the second liquid cooling plates are arranged at an angle to the first liquid cooling plate.

[0011] In some embodiments, the first distribution pipe is connected to both ends of the second liquid cooling plate.

[0012] In some embodiments, the second liquid cooling plate includes a liquid cooling plate body and a connecting portion provided at an end of the liquid cooling plate body.

[0013] In some embodiments, a pipe joint is provided on the connecting portion, and two adjacent second liquid cooling plates are connected to each other via a connecting pipe connected to the pipe joint.

[0014] In some embodiments, the connecting portion is smaller than the liquid cooling plate body, so that the liquid cooling plate bodies and the connecting portions of two adjacent second liquid cooling plates form an escape space.

[0015] In some embodiments, the cooling assembly further includes a third liquid cooling element for being arranged on the second side of the battery cell assembly; the first liquid cooling element, the second liquid cooling element and the third liquid cooling element are connected; the first liquid cooling element and the third liquid cooling element are both arranged at an angle to the second liquid cooling element.

[0016] In some embodiments, the third liquid cooling component includes a plurality of liquid cooling tubes arranged side by side and a second distribution pipe for connecting the plurality of liquid cooling tubes; the second distribution pipe is connected to both ends of the plurality of liquid cooling tubes.

[0017] In some embodiments, the third liquid-cooling element is made of aluminum or polymer material; and the melting point temperature of the third liquid-cooling element is 120° C. to 600° C.

[0018] In a second aspect of the present application, a power battery is provided, comprising:

[0019] The frame structure includes a frame for connecting the vehicle and a first crossbeam provided in the frame, wherein the inner cavity of the frame is divided into a control compartment and a battery compartment by the first crossbeam;

[0020] an upper cover connected to the frame structure and covering an upper opening of the inner cavity of the frame;

[0021] A battery cell assembly is provided in the battery compartment of the frame structure;

[0022] A circuit assembly is provided in the control cabin of the frame structure and is electrically connected to the battery core assembly;

[0023] In the cooling assembly of the first aspect, the first liquid cooling member is connected to the frame structure and covers the lower opening of the inner cavity of the frame, and the second liquid cooling member is arranged between adjacent battery cells of the battery cell assembly.

[0024] In some embodiments, the battery cell assembly is disposed in the battery compartment in a pressurized state; and the high-voltage connection lines and the low-voltage connection lines between the battery cell assembly and the circuit assembly are both close to the first beam.

[0025] In some embodiments, the circuit assembly includes an electrically connected control unit and a power distribution device, the power distribution device includes a shell and a copper busbar assembly and one or more temperature sensors installed on the shell, the copper busbar assembly is electrically connected to the battery core assembly, the temperature sensor is located in the inner cavity of the shell and is electrically connected to the control unit, the copper busbar assembly is bent toward one side of the shell so that part of the copper busbar assembly is exposed to the shell and is in thermal contact with the first liquid cooling part.

[0026] In some embodiments, the upper cover is connected to the frame structure by fasteners, and the fasteners are provided with elastic support portions so that when the battery pack is installed on the vehicle, the support portions are supported between the upper cover and the floor of the vehicle body, and the support portions are in contact with the floor.

[0027] In some embodiments, a fire-retardant plate is provided between the upper cover and the battery core assembly.

[0028] In some embodiments, a bottom guard plate is provided below the first liquid cooling component, and the bottom guard plate is connected to the frame structure.

[0029] In some embodiments, the frame structure further includes at least one second cross beam and at least one longitudinal beam, and the second cross beam and the longitudinal beam are both located in the battery compartment to divide the battery compartment into more than four battery sub-compartments; the battery cell units of the battery cell assembly are arranged one by one in the corresponding battery sub-compartments.

[0030] In some embodiments, an avoidance groove is provided on the second crossbeam.

[0031] In some embodiments, both ends of the longitudinal beam are provided with a recessed area; the bottom wall of the recessed area is provided with a through hole for the pipeline to pass through; the bottom wall of the recessed area is provided with an installation hole for installing a sensor.

[0032] In some embodiments, the cooling assembly further includes a third liquid cooling component disposed above the battery cell assembly, wherein the third liquid cooling component corresponds to a position of an explosion-proof valve port of the battery cell.

[0033] In some embodiments, the power battery further includes a coolant leakage detection device electrically connected to the circuit assembly, and the coolant leakage detection device is disposed at the lowest point of the battery compartment.

[0034] In some embodiments, the power battery further includes a temperature detection device electrically connected to the circuit assembly, wherein the temperature detection device is installed in the mounting hole and is used to detect the temperature of the coolant in the cooling assembly.

[0035] In a third aspect of the present application, a fast charging thermal management control method for a power battery based on the second aspect is provided. The fast charging thermal management control method comprises the following steps:

[0036] The circuit component obtains the temperature t of the battery cell in the battery cell component;

[0037] When the temperature t reaches a set temperature T1 or higher, the circuit component controls the coolant inside the cooling component to circulate; when the temperature t reaches a set temperature T2 or lower, the circuit component controls the coolant inside the cooling component to not circulate;

[0038] When the circuit component obtains the leakage warning signal of the coolant leakage detection device, the circuit component communicates the leakage warning signal to the entire vehicle and reports it.

[0039] In a fourth aspect of the present application, a vehicle is provided, comprising a vehicle body and the power battery described in the second aspect, wherein the power battery is mounted on the vehicle body.

[0040] A cooling assembly provided according to one or more embodiments of the present application is used to cool the battery cell assembly of a power battery. The cooling assembly includes a first liquid cooling element and a second liquid cooling element. The first liquid cooling element is arranged on the first side of the battery cell assembly to cool the top or bottom of the battery cell assembly. The second liquid cooling element is arranged between adjacent battery cells of the battery cell assembly, and the plane where the second liquid cooling element is located is arranged at an angle to the plane where the first liquid cooling element is located. A three-dimensional cooling structure is formed by the first liquid cooling element and the second liquid cooling element, and the second liquid cooling element is arranged between adjacent battery cells and can be in thermal contact with the large surface of the battery cell (the largest side surface in the battery cell). In the super-fast charging scenario, the heat generated in the middle of the battery cell can be effectively brought out, so that the battery cell operates in the optimal operating temperature range (≤40°C), meeting the thermal management requirements of 4C super-fast charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions in the embodiments of the present application, a brief introduction will be given below to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0042] Figure 1 An exploded view of a cooling assembly in accordance with one or more embodiments of the present application is shown.

[0043] Figure 2 Shown Figure 1 Assembly structure diagram of the cooling component and the power battery frame.

[0044] Figure 3 Shown Figure 2 A partial enlarged view of point A.

[0045] Figure 4 The figure shows the assembly structure of the cooling assembly and the frame of the power battery in one or more embodiments of the present application. For the convenience of display, the third liquid cooling part is exploded.

[0046] Figure 5 An exploded view of a power battery in one or more embodiments of the present application is shown.

[0047] Figure 6 Shown Figure 5 Schematic diagram of the structure of the frame structure in the power battery.

[0048] Figure 7 Shown Figure 5 Schematic diagram of the structure of the frame structure, upper cover and bottom guard plate in the power battery.

[0049] Figure 8 Shown Figure 5 Exploded diagram of the power distribution device in the power battery.

[0050] Figure 9 Shown Figure 8 Schematic diagram of the structure of the power distribution device after removing the upper shell.

[0051] Figure 10 Shown Figure 8 Bottom view of the power distribution unit with the insulating thermal pad removed.

[0052] Figure 11 A schematic diagram of the assembly structure of the power battery and the vehicle body in one or more embodiments of the present application is shown.

[0053] Figure 12 A circuit topology diagram of a power battery in one or more embodiments of the present application is shown.

[0054] Figure 13 A block diagram of a fast charging thermal management control method in one or more embodiments of the present application is shown.

[0055] Description of reference numerals:

[0056] 100-frame structure, 101-control cabin, 102-battery cabin, 103-mounting hole, 104-battery sub-cabinet; 110-frame, 111-side beam, 112-frame crossbeam, 113-facade portion, 114-mounting portion; 120-first crossbeam; 130-second crossbeam, 131-avoidance groove; 140-longitudinal beam, 141-recessed area, 142-through hole, 143-mounting hole.

[0057] 200-battery cell assembly, 210-battery cell unit, 201-explosion-proof valve port.

[0058] 300-upper cover, 301-upper cover mounting hole.

[0059] 400-cooling assembly, 410-first liquid cooling element, 411-first liquid cooling plate, 412-water inlet pipe, 413-water outlet pipe, 420-second liquid cooling element, 421-second liquid cooling plate, 4211-liquid cooling plate body, 4212-connecting portion, 4213-pipe joint, 422-first distribution pipe, 4221-pipe section, 423-avoidance space, 430-third liquid cooling element, 431-liquid cooling pipe, 432-second distribution pipe; 440-connecting pipe.

[0060] 500-circuit assembly, 510-control unit, 511-master control unit, 512-slave control unit; 520-power distribution device; 521-housing, 5211-upper housing, 5212-lower housing; 522-copper busbar assembly, 5221-first copper busbar, 5222-second copper busbar, 5223-third copper busbar, 5224-fourth copper busbar, 5225-fifth copper busbar, 5226-battery positive electrode connecting copper busbar, 5227-seventh copper busbar, 5228-eighth copper busbar, 5229-battery negative electrode Connecting copper bus, 522a-avoidance area, 522b-parallel pin, 522c-main body, 522d-connecting part, 522e-through hole; 523-temperature sensor; 524-relay, 5241-pre-charge relay, 5242-main positive relay, 5243-fast charge positive relay, 5244-main negative relay, 5245-fast charge negative relay; 525-current sensor; 526-fuse; 527-insulating thermal pad; 530-high voltage connector, 540-low voltage connector.

[0061] 600- Fire retardant board. 700- Bottom guard plate. 800- Explosion-proof valve. 900- Thermal runaway sensor. 1000- Power battery.

[0062] 2000-Body, 2100-Floor, 2200-Sill beam. DETAILED DESCRIPTION

[0063] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0064] In addition, this application may repeat reference numbers and / or reference letters in different examples. This repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or settings discussed. In addition, this application provides examples of various specific processes and materials, but those of ordinary skill in the art will recognize the application of other processes and / or the use of other materials.

[0065] In the related art, the design of the water cooling component is relatively simple, with only single upper cooling, or single lower cooling, or combined upper and lower cooling. The battery cell can be understood as a rectangular parallelepiped (the battery cells of some battery packs may be cylindrical), and its dimensions satisfy the following: height H> length L> width B. In order to place more battery cells, the battery cells are usually arranged vertically, that is, the height H is parallel to the vertical direction, and the two opposite sides formed by the length and width are the upper surface (also called the top surface) and the lower surface (also called the low surface). The existing cooling components are all for cooling the upper surface and / or the lower surface. The large surface of the battery cell, that is, the two opposite sides formed by the length and height, are not cooled. In the super fast charging (such as 4C super fast charging) usage scenario, the heat generated in the middle (large surface) of the battery cell cannot be effectively removed, thereby limiting the charging rate.

[0066] To this end, one or more embodiments of the present application provide a cooling assembly, a power battery, a fast charging thermal management control method and a vehicle, which can solve the problems of related technologies to a certain extent by cooling the large surface of the battery cell through a three-dimensional cooling structure.

[0067] In a first embodiment of the present application, a cooling assembly for cooling a cell assembly of a power battery is provided. Figure 1 and Figure 4, showing the overall structure of the cooling assembly in different embodiments. The cooling assembly 400 includes a first liquid cooling member 410 and a second liquid cooling member 420. The first liquid cooling member 410 is arranged on the first side of the battery cell assembly 200 to cool the upper or lower part of the battery cell assembly 200. The second liquid cooling member 420 is arranged between adjacent battery cells of the battery cell assembly 200, and the plane where the second liquid cooling member 420 is located is arranged at an angle to the plane where the first liquid cooling member 410 is located. A three-dimensional cooling structure is formed by the first liquid cooling member 410 and the second liquid cooling member 420, and the second liquid cooling member 420 is arranged between adjacent battery cells. It can be in thermal contact with the large surface of the battery cell (the largest side surface in the battery cell). In the super-fast charging scenario, it can effectively bring out the heat generated in the middle of the battery cell, meeting the thermal management requirements of 4C super-fast charging.

[0068] The second liquid cooling element 420 is connected to the first liquid cooling element 410. Either the second liquid cooling element 420 or the first liquid cooling element 410 can be connected to an external coolant pipeline to facilitate the circulation of coolant within the cooling assembly 400. The second liquid cooling element 420 is positioned between adjacent battery cells in the battery cell assembly 200. The second liquid cooling element 420 can be directly in contact with the battery cells, or a thermally conductive protective structure can be provided between the second liquid cooling element 420 and the battery cells. Alternatively, if the battery cell assembly 200 includes multiple battery modules, the second liquid cooling element 420 can be positioned between adjacent battery modules. This application does not limit the specific configuration of the second liquid cooling element 420, as long as heat conduction between the large surface of the battery cells and the second liquid cooling element 420 is possible.

[0069] The first liquid-cooling element 410 and the second liquid-cooling element 420 can be liquid-cooling plates or liquid-cooling tubes. The liquid-cooling tubes are specifically in the form of multiple pipes arranged side by side. Therefore, whether it is a liquid-cooling plate or a liquid-cooling tube, a cooling plane will be formed. The plane where the second liquid-cooling element 420 is located is set at an angle to the plane where the first liquid-cooling element 410 is located. It can be understood that the cooling plane formed by the second liquid-cooling element 420 is set at an angle to the cooling plane formed by the first liquid-cooling element 410, thereby forming a spatial three-dimensional cooling structure with the first liquid-cooling element 410 and the second liquid-cooling element 420.

[0070] See also Figure 1 and Figure 4In some embodiments, both the first liquid cooling element 410 and the second liquid cooling element 420 are liquid cooling plates. Specifically, the first liquid cooling element 410 includes a first liquid cooling plate 411; the second liquid cooling element 420 includes multiple second liquid cooling plates 421 and a first distribution pipe 422 for connecting the multiple second liquid cooling plates 421. The second liquid cooling plates 421 are arranged at an angle to the first liquid cooling plates 411. The first liquid cooling plates 411 can cool the top or bottom surfaces of all battery cells in the battery cell assembly 200. Because the battery cell assembly 200 typically contains hundreds of battery cells, multiple second liquid cooling plates 421 are provided, spaced apart to form multiple distributed cooling points. In some embodiments, the battery cell assembly 200 is spatially divided into multiple battery cell units 210, each battery cell unit 210 being arranged in a relatively independent space. In this case, the number of second liquid cooling plates 421 can be equal to or a multiple of the number of battery cell units 210.

[0071] The first distribution pipe 422 can be disposed above, below, on the side, or at both ends of the second liquid cooling plate 421. In some embodiments, see Figure 1 The first distribution pipe 422 is connected to both ends of the second liquid cooling plate 421 , so that the first distribution pipe 422 does not occupy the installation space of the battery cell assembly 200 as much as possible.

[0072] See also Figure 1 In some embodiments, the second liquid cooling plate 421 includes a liquid cooling plate body 4211 and a connecting portion 4212 disposed at the end of the liquid cooling plate body 4211. A pipe joint 4213 is disposed on the connecting portion 4212. Two adjacent second liquid cooling plates 421 are connected via a connecting pipe 440 connected to the pipe joint 4213. The connecting pipe 440 can be a flexible tube to improve the adaptability of the second liquid cooling plate 421 in the longitudinal direction. The axis of the pipe joint 4213 should be arranged at an angle to the liquid cooling plate body 4211 (or the liquid cooling plate body 4211 and the connecting portion 4212) to ensure that the connecting pipe 440 does not encroach on the installation space of the second liquid cooling plate 421 and facilitate connection and insertion of the connecting pipe 440. The second liquid cooling plate 421 can be connected to the first distribution pipe 422 via the pipe joint 4213 on the connecting portion 4212, or the liquid cooling plate body 4211 or the connecting portion 4212 can be directly connected to the first distribution pipe 422.

[0073] The connecting portion 4212 can be a portion extending outward from the liquid cooling plate body 4211, or it can be an additional hollow plate. When the connecting portion 4212 is also a plate, the connecting portions 4212 of the two second liquid cooling plates 421 adjacent end to end can partially overlap or completely overlap. The size of the connecting portion 4212 is smaller than the liquid cooling plate body 4211, so that the liquid cooling plate body 4211 and the connecting portion 4212 of the two second liquid cooling plates 421 adjacent end to end are combined to form an avoidance space 423. In some embodiments, the height of the connecting portion 4212 is smaller than the liquid cooling plate body 4211, and the connecting portion 4212 is flush with the top of the liquid cooling plate body 4211, then a space will be formed below the connecting portion 4212 to avoid other structures in the power battery 1000.

[0074] See also Figure 4 In some embodiments, the cooling assembly 400 further includes a third liquid cooling element 430, which is disposed on the second side of the battery cell assembly 200. Specifically, the first and third liquid cooling elements 410, 430 are disposed on the upper and lower sides of the battery cell assembly 200, while the second liquid cooling element 420 is disposed within the battery cell assembly 200. The second liquid cooling element 420 is disposed at an angle relative to the planes of the first and third liquid cooling elements 410, 430, thereby forming a three-dimensional cooling structure with upper, middle, and lower layers. The first, second, and third liquid cooling elements 410, 420, 430 are interconnected, allowing coolant to flow between them. The first, second, and third liquid cooling elements 410, 420, 430 can be interconnected sequentially or connected in parallel to an external cooling liquid pipeline.

[0075] In some embodiments, the second liquid cooling element 420 and the third liquid cooling element 430 are both connected to the first liquid cooling element 410. The first liquid cooling element 410 is provided with a water inlet pipe 412 and a water outlet pipe 413 connected to an external cooling liquid pipeline. Figure 4 In some embodiments, the third liquid-cooling element 430 includes a plurality of liquid-cooling tubes 431 arranged side by side and a second distribution pipe 432 for connecting the plurality of liquid-cooling tubes 431. The second distribution pipe 432 and the first distribution pipe 422 are both connected to the first liquid-cooling plate 411. The connection between the second distribution pipe 432 and the first liquid-cooling plate 411 can overlap with the connection between the first distribution pipe 422 and the first liquid-cooling plate 411. That is, the second distribution pipe 432 is directly connected to the first distribution pipe 422, and the first distribution pipe 422 is directly connected to the first liquid-cooling plate 411. In some embodiments, the second distribution pipe 432 is also connected to both ends of the plurality of liquid-cooling tubes 431, so that the second distribution pipe 432 does not encroach on the installation space of the battery cell assembly 200 as much as possible.

[0076] In addition to providing cooling, the third liquid cooling element 430 also serves as a safety precaution in the event of a thermal runaway fire within the battery pack. In some embodiments, the third liquid cooling element 430 can be actively or passively destroyed. For example, the melting point of the material of the third liquid cooling element 430 is lower than the temperature of the ejected material from the thermally runaway battery cells, causing it to melt through. Alternatively, upon detecting thermal runaway within the battery pack, the third liquid cooling element 430 can be damaged by localized impact (e.g., puncturing the third liquid cooling element 430 with an external puncture structure) or by rupturing a localized weak point (e.g., by providing a weak point on the third liquid cooling element 430 that is easily breached by a certain pressure of coolant). During normal use, the third liquid cooling element 430 cools the battery cells. If thermal runaway occurs within the battery pack and the battery cells emit high-temperature smoke, gas, or dust, the fire extinguishing system is passively triggered, causing the coolant within the third liquid cooling element 430 to flow out and extinguish the fire.

[0077] In some embodiments, the third liquid cooler 430 can be made of aluminum or a polymer, such as PET (polyethylene terephthalate) polymer. In some embodiments, the third liquid cooler 430 is made of tertiary aluminum, such as 3003 aluminum plate or 3004 aluminum plate; in some embodiments, the third liquid cooler 430 is made of PET polymer. The material selection for the third liquid cooler 430 should ensure that its melt-through temperature is between 120°C and 600°C. If the melt-through temperature is below 120°C, the third liquid cooler 430 is susceptible to accidental damage. If the melt-through temperature is above 600°C, the third liquid cooler 430 is unlikely to break or melt through, rendering it ineffective in extinguishing the fire. During normal battery pack operation, the third liquid cooler 430 cools the upper portion of the battery cells. In the event of thermal runaway, the hot air from the battery cells melts or penetrates the third liquid cooler 430, allowing the coolant within the third liquid cooler 430 to flow out and extinguish the fire.

[0078] The second embodiment of the present application provides a power battery 1000. Figure 5 The power battery 1000 includes a frame structure 100, a battery cell assembly 200, an upper cover 300, a circuit assembly 500, and a cooling assembly 400 according to any one of the embodiments of the first aspect. Figure 6The frame structure 100 includes a frame 110 and a first crossbeam 120 connected to the frame 110. The frame 110 is provided with a mounting hole 103 for connecting to a vehicle so as to install the power battery 1000 on the vehicle. The first crossbeam 120 is provided in the frame 110. The inner cavity of the frame 110 is divided into a control compartment 101 and a battery compartment 102 by the first crossbeam 120. The upper cover 300 is connected to the frame structure 100 and covers the upper opening of the inner cavity of the frame 110. The battery cell assembly 200 is provided in the battery compartment 102 of the frame structure 100. The circuit assembly 500 is provided in the control compartment 101 of the frame structure 100 and is electrically connected to the battery cell assembly 200. The first liquid cooling element 410 of the cooling assembly 400 is connected to the frame structure 100 and covers the lower opening of the inner cavity of the frame 110. The second liquid cooling element 420 of the cooling assembly 400 is provided between adjacent battery cells of the battery cell assembly 200.

[0079] See also Figure 5 In some embodiments, the battery cell assembly 200 includes a number of battery cells distributed in a matrix. By setting the number and relationship of series and parallel connections of each battery cell, the battery cell assembly 200 can achieve high and low voltage output on the same side of the first beam 120, that is, the high-voltage connection line and the low-voltage connection line connecting the battery cell assembly 200 and the circuit assembly 500 are both close to the first beam 120, and then establish a high and low voltage connection relationship with the circuit assembly 500 in the control cabin 101, realizing the interconnection and interaction of low-voltage sampling and high-voltage circuits, and realizing high integration of local positions.

[0080] See also Figure 5 and Figure 12 In some embodiments, the circuit assembly 500 includes a control unit 510 and a power distribution device 520. The control unit 510 may be a BMS (battery management system), and the power distribution device 520 may be a BDU (battery energy distribution unit, also known as a high-voltage distribution box). The control unit 510 and the power distribution device 520 are arranged side by side in a transverse direction (the axial direction of the beam). In some embodiments, the control unit 510 adopts a master-multiple slave topology framework, including a master control unit 511 and two or more slave control units 512.

[0081] See also Figure 12 In some embodiments, the power battery 1000 is provided with a thermal runaway sensor 900 , which is electrically connected to the control unit 510 . The control unit 510 determines whether thermal runaway occurs in the power battery 1000 based on a feedback signal from the thermal runaway sensor 900 .

[0082] See also Figure 5 and Figure 12The frame structure 100 is provided with a plurality of high-voltage connectors 530 and low-voltage connectors 540 electrically connected to the circuit assembly 500. The high-voltage connectors 530 and the low-voltage connectors 540 are both located on the frame beams 112 of the frame structure 100, and can be specifically provided on the frame beams 112 close to the control cabin 101. A plurality of explosion-proof valves 800 can also be provided on the frame beams 112 at both ends of the frame structure 100, such as Figure 5 shown.

[0083] See also Figure 5 and Figure 12 In some embodiments, four high-voltage connectors 530 are provided: a high-voltage connector 531 for connecting to the power battery charging harness, a high-voltage connector 532 for connecting to the onboard charger, a high-voltage connector 533 for connecting to the front-drive motor, and a high-voltage connector 534 for connecting to the rear-drive motor. The high-voltage connectors 530 can be directly connected to the copper busbar assembly 522 of the power distribution device 520 or connected to the copper busbar assembly 522 of the power distribution device 520 via cables.

[0084] See also Figure 8 、 Figure 9 and Figure 10 In some embodiments, the power distribution device 520 includes a shell 521 and an electrical unit installed in the shell 521. The electrical unit includes a copper busbar assembly 522 and one or more temperature sensors 523. The temperature sensor 523 is located in the inner cavity of the shell 521. The copper busbar assembly 522 is bent toward one side of the shell 521 so that part of the copper busbar assembly 522 is exposed outside the shell 521. The shell 521 provides an installation base for the electrical unit. At the same time, the shell 521 can also be connected to the frame 700 of the power battery to achieve the fixation of the high-voltage distribution box. The power distribution device 520 adopts internal temperature monitoring and active cooling of the copper busbar to improve the heat dissipation performance of the distribution box, collect and monitor the temperature inside the distribution box in real time, ensure that the temperature of the distribution box is normal, and improve the current carrying capacity to cope with the large heat generated by 4C super fast charging and prevent ablation and fire problems.

[0085] Temperature sensor 523 is used to detect the temperature inside the high-voltage distribution box, monitor and record the temperature of key locations in real time, and monitor, collect and report the temperature in real time. The installation position of temperature sensor 523 should be close to the copper busbar assembly. The specific installation position can be determined based on the high temperature point determined by simulation analysis and placed in a location with higher temperature. The detection signal of temperature sensor 523 is fed back to the controller (power battery controller or vehicle controller), and the controller controls the power battery to reduce the charging and discharging power or power off based on the signal fed back by temperature sensor 523.

[0086] The copper busbar assembly 522 is used to carry current, so heat is generated during operation. The copper busbar assembly 522 is bent toward one side of the housing 521 so that part of the copper busbar assembly 522 is exposed to the housing 521. The copper busbar assembly 522 exposed to the housing 521 can be in contact with an external cooling assembly (such as a liquid cooling plate of a power battery) or in contact with the air for cooling. In some embodiments, the housing 521 is provided with an extension hole for the copper busbar assembly 522 to extend out, and a portion of the copper busbar assembly 522 extends out of the housing 521 through the extension hole so that the bent portion of the copper busbar assembly 522 protrudes from the outer surface of the housing 521. In some embodiments, the housing 521 is provided with an embedded hole, and the bent portion of the copper busbar assembly 522 is embedded in the embedded hole so that the copper busbar assembly 522 is coplanar with the surface of the embedded hole of the housing 521, or the copper busbar assembly 522 protrudes from the surface of the embedded hole. Since the copper busbar assembly 522 can be cooled by external heat dissipation, the risk of overheating failure is reduced, and the thermal management requirements of 4C super fast charging can be met.

[0087] See also Figure 8 and Figure 9 In some embodiments, the electrical unit further includes one or more relays 524; the one or more relays 524 are disposed horizontally within the inner cavity of the housing 521. Relays 524 typically include a coil and contacts, with the contacts being classified as normally open and normally closed. Normally open contacts are also called make contacts, and normally closed contacts are also called break contacts. Relays 524 are disposed horizontally, meaning they are not arranged vertically. The two contact blades are spaced apart horizontally. Compared to a vertical arrangement of relays 524, which can easily lead to accidental connection / disconnection due to vehicle jolting, a horizontal arrangement of relays 524 ensures that the two contacts remain connected or disconnected unaffected by vehicle jolting. Furthermore, the horizontal arrangement of relays 524 saves space in the height (Z-direction) of the power distribution device 520, improving the space utilization of the power battery. At the same time, the horizontal arrangement of the relay 524 increases the bottom side area of ​​the distribution device 520, provides installation space for setting up a large-sized copper busbar assembly 522, increases the contact area between the copper busbar assembly 522 and the external cooling assembly (such as the first liquid cooling component 410), and improves the heat dissipation efficiency.

[0088] In some embodiments, the number of relays 524 is one, two, three, or four, etc. The number of relays 524 can be determined according to the needs. Figure 9There are five relays 524, namely a pre-charge relay 5241, a main positive relay 5242, a fast-charge positive relay 5243, a main negative relay 5244, and a fast-charge negative relay 5245. Each of these relays 524 controls the on / off of its respective circuits. Specifically, the pre-charge relay 5241 controls the on / off of the pre-charge circuit; the main positive relay 5242 and the main negative relay 5244 control the on / off of the connection between the high-voltage distribution box and the battery pack, enabling power on and off; and the fast-charge positive relay 5243 and the fast-charge negative relay 5245 control the on / off of the fast-charge circuit.

[0089] In some embodiments, please refer to Figure 9 and Figure 12 The electrical unit also includes a current sensor 525, which is used to detect the current passing through the copper busbar assembly 522 to monitor the working status of the copper busbar assembly 522 and provide data support for the safe operation of the power battery. The high-voltage connector 530 can be understood as a high-voltage connector. There are multiple high-voltage connectors 530, such as two, three, four, or five. There are multiple high-voltage connectors 530, which can be used to connect the power battery charging harness, vehicle heater, front-wheel drive motor, rear-wheel drive motor, on-board charger, etc.

[0090] In some embodiments, see Figure 8 、 Figure 9 and Figure 10 The copper busbar assembly 522 includes a first copper busbar 5221 connecting the current sensor 525 and the main positive relay 5242, a second copper busbar 5222 connecting the main positive relay 5242 and the fast charging positive relay 5243, a third copper busbar 5223 connecting the fast charging positive relay 5243 and the corresponding high-voltage connector 530 (i.e., the high-voltage connector 531), a fourth copper busbar 5224 connecting the fast charging negative relay 5245 and the corresponding high-voltage connector 530 (i.e., the high-voltage connector 531), and a fifth copper busbar 5225 connecting the main negative relay 5244 and the fast charging negative relay 5245. In some embodiments, the first copper bar 5221, the second copper bar 5222, the third copper bar 5223, the fourth copper bar 5224 and the fifth copper bar 5225 are all bent, and the bent parts of the first copper bar 5221, the second copper bar 5222, the third copper bar 5223, the fourth copper bar 5224 and the fifth copper bar 5225 are exposed to the shell 521 to dissipate heat through heat exchange with the external cooling component 400 or air flow.

[0091] In some embodiments, the first copper bar 5221, the second copper bar 5222, the third copper bar 5223, the fourth copper bar 5224, and the fifth copper bar 5225 are sequentially arranged along the length of the housing 521, that is, along the length or width of the power battery, to increase the heat dissipation area of ​​the copper bar assembly 522 exposed to the housing 521. In some embodiments, considering that the high-voltage connector 531 connected to the power battery charging harness withstands the highest voltage, the high-voltage connector 531 is connected to both the third copper bar 5223 and the fourth copper bar 5224, and the other high-voltage connectors 530 are electrically connected to the copper bar assembly 522 via cables.

[0092] In some embodiments, see Figure 10 The second copper bar 5222, the third copper bar 5223 and the fifth copper bar 5225 are all special-shaped copper bars; the special-shaped copper bar is provided with an avoidance area 522a and / or a parallel pin 522b. In some embodiments, the special-shaped copper bar is provided with an avoidance area 522a for avoiding other structural parts. In some embodiments, the special-shaped copper bar is provided with a parallel pin 522b. The parallel pins 522b of the special-shaped copper bar can be two, three, or four, so that the power distribution unit (BDU) has several parallel high-voltage output terminals, which output voltage to the vehicle's front drive motor, rear drive motor, car heater (PTC for short) and on-board charger (OBC for short). The special-shaped copper bar is provided with a parallel pin 522b. Under the premise of meeting the current carrying capacity, the parallel pin 522b and the connection between the two parallel pins 522b are exposed to the shell 521, which increases the surface area of ​​the copper bar exposed to the shell 521 and improves the heat dissipation area. In some embodiments, the special-shaped copper busbar may be configured to have both a avoidance area 522a for avoiding other structural components and a parallel pin 522b.

[0093] See also Figure 10 In some embodiments, the second copper bar 5222 and the fifth copper bar 5225 are both provided with a plurality of parallel pins 522b; the third copper bar 5223 has an avoidance area 522a for avoiding other structural parts. The third copper bar 5223 is a three-dimensional special-shaped copper bar, which can reasonably utilize the remaining space inside the high-voltage distribution box and reduce the volume of the high-voltage distribution box.

[0094] In some embodiments, current sensor 525 is a Hall effect sensor, and copper bar assembly 522 also includes a sixth copper bar (obstructed by the coil and not visible in the figure) that matches the Hall effect sensor. The sixth copper bar is narrower than the first copper bar 5221, the second copper bar 5222, the third copper bar 5223, the fourth copper bar 5224, and the fifth copper bar 5225. The sixth copper bar is narrower to accommodate Hall effect sensors of different brands and models, ensuring that it can pass through the Hall effect coil of the Hall effect sensor. In some embodiments, the specifications of the sixth copper bar are: a cross-sectional width of 16 to 22 mm and a cross-sectional height (i.e., copper bar thickness) of 6 to 10 mm. For example, the cross-sectional dimensions of the sixth copper bar are 20 mm × 8 mm, or 18 mm × 10 mm. The width of the first, second, third, fourth, and fifth copper bars 5221, 5222, 5223, 5224, and 5225 at their narrowest points (at the pins) is 28 to 32 mm, and their thickness is 4 to 6 mm. For example, the cross-sectional dimensions of the narrowest points of the first, second, third, fourth, and fifth copper bars 5221, 5222, 5223, 5224, and 5225 are 30 mm × 5 mm or 28 mm × 6 mm, respectively. The sixth copper bar is narrower and thicker to meet load requirements and accommodate Hall effect sensors of varying sizes. The remaining copper bars are wider and thinner to meet complex requirements, increase heat dissipation area, and improve heat dissipation efficiency.

[0095] In some embodiments, see Figure 8 、 Figure 9 and Figure 10 The copper busbar assembly 522 also includes a seventh copper busbar 5227 and an eighth copper busbar 5228 for connecting the battery modules of the cell assembly 200 in series. This means that two battery modules of the cell assembly 200 are connected in series via the copper busbar assembly 522 of the high-voltage distribution box. The seventh copper busbar 5227 and the eighth copper busbar 5228 are electrically connected, forming a circuit connecting the two series-connected battery modules. The seventh copper busbar 5227 and the eighth copper busbar 5228 connect the battery modules in series to form the cell assembly 200.

[0096] In some embodiments, see Figure 9 and Figure 12The electrical unit also includes a fuse 526, which is connected in series between the seventh copper bar 5227 and the eighth copper bar 5228 to achieve power outages between different battery modules. In the event of thermal runaway, the fuse 526 will disconnect the two connected battery modules after it blows, dividing the battery cell assembly 200 into two non-conductive battery units. This makes the number of cells in the battery unit experiencing thermal runaway significantly less than that in the battery cell assembly 200, thereby reducing short-circuit current and heat generation during thermal runaway, thereby avoiding greater hazards. In some embodiments, the seventh copper bar 5227 and the eighth copper bar 5228 are located on the side of the power distribution device 520 and are close to the battery cell assembly 200. The fuse 526 can be an intelligent fuse 526 that can be actively or passively blown, forming active and passive insurance, thereby improving safety performance.

[0097] In some embodiments, see Figure 10 The copper busbar assembly 522 also includes a battery positive electrode connecting copper busbar 5226 and a battery negative electrode connecting copper busbar (not shown in the figure), wherein the battery positive electrode connecting copper busbar 5226 is used to connect to the positive electrode of the battery cell assembly 200, and the battery negative electrode connecting copper busbar is used to connect to the negative electrode of the battery cell assembly 200. The battery positive electrode connecting copper busbar 5226 and the battery negative electrode connecting copper busbar can be optionally arranged inside the shell 521 or outside the shell 521 to reduce the volume of the distribution device 520.

[0098] See also Figure 10 In some embodiments, the copper busbar in the copper busbar assembly 522 (which can refer to any of the copper busbars described above) includes a main body 522c and a connecting portion 522d for connecting to a high-voltage fastener. The surface of the main body 522c is provided with an insulating layer or sprayed with epoxy resin powder for insulation protection. The surface of the connecting portion 522d is nickel-plated to prevent electrochemical corrosion while also being conductive. In some embodiments, the connecting portion 522d is located outside or inside the housing 521. The high-voltage fastener is a high-voltage bolt, and current is transmitted through the main body 522c, the nickel-plated layer, and the high-voltage bolt. The connecting portion 522d is provided with a through-hole 522e for the high-voltage fastener to pass through. The through-hole 522e can be a plain hole or a threaded hole, and the material surrounding the through-hole 522e constitutes the connecting portion 522d. The connecting portion 522d of the copper busbar can be connected to the high-voltage connector 530 via the high-voltage fastener, or to the connecting portion 522d of another copper busbar via the high-voltage fastener, or to a high-voltage cable via the high-voltage fastener.

[0099] The copper busbar assembly 522 at the bottom of the power distribution device 520 can be either a busbar or a high-voltage busbar. The high-voltage busbar connects the battery to the relay 524, and then to the high-voltage connector 530, forming a power circuit. Because the external cooling assembly dissipates heat efficiently, both the copper busbar assembly 522 and the relay 524 can be smaller, saving space and increasing the current carrying rate to meet the needs of super-fast charging.

[0100] See also Figure 9 In some embodiments, two temperature sensors 523 are provided, both for detecting ambient temperature. One temperature sensor 523 is located near the sixth copper busbar, and the other temperature sensor 523 is located near the first copper busbar 5221 and the main positive relay 5242, where there are more copper busbar joints and the temperature is higher.

[0101] In some embodiments, see Figure 8 The shell 521 includes an upper shell 5211 and a lower shell 5212, and the upper shell 5211 and the lower shell 5212 together form an inner cavity; the upper shell 5211 and the lower shell 5212 are both injection molded parts, and the upper shell 5211 and the lower shell 5212 are directly injection molded to avoid short circuit problems caused by debris entering the shell 521; in some embodiments, the lower shell 5212 is provided with a protruding hole or an embedded hole, the electrical unit is located in the inner cavity, the bent portion of the copper busbar assembly 522 protrudes from the protruding hole and is exposed to the shell 521, or the bent portion of the copper busbar assembly 522 is located in the embedded hole, and the bent portion is coplanar with the surface where the embedded hole is located or protrudes from the surface where the embedded hole is located, so as to contact and exchange heat with the external cooling component. Since the copper busbar assembly 522 is partially exposed to the shell 521, thereby dissipating heat with the external cooling component, there is no need to open heat dissipation holes in the upper shell 5211 and the lower shell 5212, thereby improving the mechanical strength of the shell 521 and reducing the cost of the production process.

[0102] In some embodiments, see Figure 8 The power distribution device 520 also includes an insulating thermal pad 527, which covers the portion of the copper busbar assembly 522 exposed to the shell 521 to insulate the copper busbar from the external cooling assembly, while also conducting heat from the copper busbar to the cooling assembly. The insulating thermal pad 527 can be provided in one, two, or three pieces, and the thickness of the insulating thermal pad 527 generally ranges from 1.5 mm to 2.5 mm. The number and thickness of the insulating thermal pad 527 can be selected independently to prevent the shell 521 from scratching or breaking the cooling assembly during driving or other vibrations due to the uneven bottom of the power distribution device 520.

[0103] See also Figure 5 and Figure 6In some embodiments, the frame structure 100 further includes one or more second crossbeams 130 and one or more longitudinal beams 140 disposed within the battery compartment 102. The battery cell assembly 200 is positioned in the battery compartment 102 in a compressed state. The first crossbeam 120, the second crossbeam 130, and the frame crossbeam 112 of the frame 110 collectively clamp the battery cell from both ends in the X-direction (the axial direction of the longitudinal beam 140), pre-tightening the battery cell within the battery compartment 102 and inhibiting expansion. The second crossbeam 130 is also provided with a plurality of mounting holes 103 for mounting bolts.

[0104] The longitudinal beams 140 of the frame structure 100 are cross-connected with the second transverse beams 130 to divide the battery compartment 102 into a plurality of battery subcompartments 104. Multiple battery cells are grouped and loaded into the battery subcompartments 104 to form a plurality of battery cell units 210. The battery cell units 210 of the battery assembly 200 are disposed in corresponding battery subcompartments 104. The battery cell units 210 in each battery subcompartment 104 of the battery assembly 200 can be collectively referred to as a battery module, or a battery module can be configured to include multiple battery cell units 210. The specific configuration is not limited in this application.

[0105] The upper cover 300 is connected to the frame structure 100 by fasteners, see Figure 5 、 Figure 7 and Figure 11 In some embodiments, the upper cover 300 is provided with a plurality of upper cover mounting holes 301 corresponding to the longitudinal beams 140 of the frame structure 100 for installing fasteners 310. The upper cover 300 is connected to the longitudinal beams 140 of the frame structure 100 via the fasteners 310. The upper cover 300 is also provided with mounting holes 103 corresponding to the mounting holes 103 on the second crossbeam 130 for installing mounting bolts. In some embodiments, bushings are provided in the upper cover mounting holes 301 and / or the mounting holes 103 of the upper cover 300 to facilitate local reinforcement of the holes during installation of the fasteners 310, thereby preventing local cracking or damage in the holes of the upper cover 300 after installation.

[0106] In some embodiments, the upper cover 300 is formed by continuous long glass fiber fabric and resin molding. The long glass fiber fabric can provide high tensile strength for the upper cover 300 body. The resin can infiltrate and solidify the glass fiber after being heated and pressurized, so that the upper cover 300 is formed according to the expected design morphological characteristics, and the molding thickness can be as low as 1mm or less, and the density can be as low as 2g / cm 3 In some embodiments, the upper cover 300 is provided with an inner concave structure and an outer convex structure, which constitute a reinforcement structure of the upper cover 300, and can improve the natural frequency of the upper cover 300 as a whole, thereby improving the rigidity in the free state.

[0107] See also Figure 11In some embodiments, the fastener 310 of the upper cover 300 is provided with an elastic support portion 320. The support portion 320 can be a support block made of an elastic material, or it can include a rigid layer and an elastic layer. When the power battery 1000 is installed in the vehicle, the support portion 320 is provided between the upper cover 300 and the floor 2100 of the vehicle body 2000, and the support portion 320 contacts the floor 2100. The support portion 320 can be compressed and filled between the upper cover 300 and the floor 2100 of the vehicle body 2000, thereby providing effective support for the floor 2100 of the vehicle body 2000.

[0108] See also Figure 5 In some embodiments, a fire retardant board, such as a mica board, is provided between the upper cover 300 and the battery cell assembly 200. The fire retardant board can be a single board or multiple boards corresponding to the small space areas within the battery compartment 102.

[0109] See also Figure 5 and Figure 7 In some embodiments, a bottom guard plate 700 is provided below the first liquid-cooling element 410. The bottom guard plate 700 is connected to the frame structure 100, and may be connected to the vertical portion 113 of the frame 110 via rivet bolts. The bottom guard plate 700 is made of a material with a greater strength than the first liquid-cooling element 410, for example, 1300 MPa high-strength steel, to protect the first liquid-cooling element 410.

[0110] In some embodiments, the water inlet pipe 412 and the water outlet pipe 413 of the cooling assembly 400 are connected to the first liquid cooling element 410 through an adapter joint. In some embodiments, the water inlet pipe 412 and the water outlet pipe 413 are both provided on the frame structure 100, see Figure 2 The inlet and outlet water pipes of the cooling assembly 400 are arranged on the frame crossbeam 112 in the frame 110 away from the control cabin 101, so that the high and low voltage outlet lines (high voltage connector 530 and low voltage connector 540) and the water pipes are located on opposite sides of the power battery 1000, reducing the safety risk of water contact with the circuit and facilitating pipeline layout.

[0111] See also Figure 5 In some embodiments, the first liquid cooling member 410 is a stamped liquid cooling plate with a large overall surface. The first liquid cooling member 410 covers the lower opening of the inner cavity of the frame 110 and is attached to the bottom plane of the frame structure 100. The first liquid cooling member 410 is fixed to the frame 110, the second crossbeam 130, and the bottom of the longitudinal beam 140 by FDS (hot melt self-tapping screws). Figure 11As shown. Because the first liquid cooling element 410 is mounted on the frame structure 100, the entire surface of the first liquid cooling element 410 achieves high rigidity, serving as a base support for the battery cells. Each battery cell in the battery cell assembly 200 is attached to the top surface of the first liquid cooling element 410, which supports the cells from below. This results in a compact Z-axis height for the entire power battery 1000, significantly enhancing its integration.

[0112] See also Figure 2 In some embodiments, the second liquid cooling unit 420 includes a plurality of second liquid cooling plates 421 and a first distribution pipe 422 for connecting the plurality of second liquid cooling plates 421. The number of the second liquid cooling plates 421 should be no less than the number of the battery cells 210 or the battery sub-compartments 104. A second liquid cooling plate 421 can be arranged in each battery sub-compartment 104. The second liquid cooling plate 421 is located in the middle of the battery cell 210, close to the symmetry plane. For example, the battery cell assembly 200 includes 6 battery cells 210 distributed in a 2*3 matrix. The second liquid cooling unit 420 includes 6 second liquid cooling plates 421, and each battery sub-compartment 104 has a second liquid cooling plate 421. Figure 2 Multiple second liquid cooling plates 421 may also be arranged in each battery sub-compartment 104, which is not limited in this application.

[0113] See also Figure 2 、 Figure 6 and Figure 7 In some embodiments, the spacing between two adjacent second liquid cooling plates 421 (including the liquid cooling plate bodies 4211) should be no less than the width of the second crossbeam 130, ensuring that the second crossbeam 130 can pass through the escape space 423 formed by the liquid cooling plate bodies 4211 and the connecting portions 4212 of the two adjacent second liquid cooling plates 421. The connecting portions 4212 are located above the second crossbeam 130, allowing the connection pipe 440 to be arranged in the space above the second crossbeam 130. In some embodiments, the second crossbeam 130 is provided with an escape groove 131, which corresponds to the position of the connecting portion 4212, providing ample space for the connection pipe 440.

[0114] See also Figure 2 、 Figure 6 and Figure 7 In some embodiments, the first distribution pipe 422 is connected to both ends of the second liquid cooling plate 421. In some embodiments, both ends of the longitudinal beam 140 are provided with a recessed area 141, through which the first distribution pipe 422 can pass to reduce the overall height of the power battery 1000. The recessed area 141 can be a groove or a through hole.

[0115] See also Figure 2 、 Figure 3 、 Figure 6 and Figure 7 In some embodiments, the recessed area 141 is an L-shaped groove. The bottom wall of the recessed area 141 is provided with a through hole 142. The pipe section 4221 in the first distribution pipe 422 that communicates with the first liquid-cooling element 410 can pass through the through hole 142. The through hole 142 can serve as a position limiter for the pipe section 4221. In some embodiments, the bottom wall of the recessed area 141 is provided with a mounting hole 143 for mounting a sensor. A temperature detection device (not shown) can be mounted in the mounting hole 143 to detect the temperature of the coolant in the cooling assembly 400. The temperature detection device is electrically connected to the circuit assembly 500, and can be electrically connected to the control unit 510 of the circuit assembly 500. The temperature detection device is mounted in the mounting hole 143, so that the probe of the temperature detection device can be applied to the pipe section 4221, shortening the length of the temperature detection device's wiring harness.

[0116] See also Figure 5 In some embodiments, the cooling assembly 400 further includes a third liquid cooling element 430, and the third liquid cooling element 430 is disposed above the battery cell assembly 200 and below the upper cover 300 (if a fire retardant plate is provided in the power battery, the third liquid cooling element 430 is located below the fire retardant plate). Figure 5 In some embodiments, the third liquid-cooling element 430 corresponds to the explosion-proof valve port 201 of the battery cell. Specifically, each liquid-cooling tube 431 of the third liquid-cooling element 430 is located above the explosion-proof valve port 201 of the battery cell. When thermal runaway occurs within the battery pack, high-temperature smoke, gas, and dust ejected from the explosion-proof valve port 201 by the faulty battery cell can rupture, pierce, melt, or penetrate the corresponding liquid-cooling tube 431. Coolant in the third liquid-cooling element 430 can then flow through the explosion-proof valve port 201 into the faulty battery cell, extinguishing the fire.

[0117] In certain embodiments, the power battery 1000 is further provided with a coolant leakage detection device (not shown in the figure), which is electrically connected to the circuit assembly 500, and may be electrically connected to the control unit 510 of the circuit assembly 500. The coolant leakage detection device is provided at the lowest point of the battery compartment 102. When the coolant leaks, it will first flow to the lowest point in the battery compartment 102. For example, a coolant leakage detection device is provided on the bottom surface of each battery sub-compartment 104. The coolant leakage detection device may use a detection wire. When a coolant leak occurs, the two detection wires are electrically connected through the leaked coolant, triggering a leakage warning signal to the control unit 510. Alternatively, when a coolant leak occurs, the detection wire contacts the leaked coolant, causing a change in resistance, triggering a leakage warning signal to the control unit 510. The specific structure of the coolant leakage detection device can refer to the relevant disclosure of the prior art and will not be repeated here.

[0118] The third embodiment of the present application provides a fast charging thermal management control method, which is applied to the power battery 1000 described in the second embodiment.

[0119] See also Figure 13 The fast charging thermal management control method includes the following steps: the circuit component 500 obtains the temperature t of the battery cell in the battery cell assembly 200; when the temperature t reaches above the set temperature T1, the circuit component 500 controls the circulation of the coolant inside the cooling component 400; when the temperature t reaches below the set temperature T2, the circuit component 500 controls the coolant inside the cooling component 400 to not circulate; when the circuit component 500 obtains the leakage warning signal of the coolant leakage detection device, the circuit component 500 communicates the leakage warning signal to the entire vehicle and reports it.

[0120] When a vehicle is connected to a super-fast charging station, the battery management system (BMS) receives a fast-charging request and checks the battery status. If the battery status check is normal, the BMS controls the relay contacts in the power distribution unit 520 (BDU) to close, starting charging. At this point, the BMS starts executing the above-mentioned fast-charging thermal management control method.

[0121] In the battery cell assembly 200, each battery cell is provided with a temperature sensor to detect the battery cell temperature. The maximum value, average value, etc. of the temperature of each battery cell can be taken as the temperature t, and this application does not impose any restrictions. When the battery temperature rises to a temperature t that reaches above the set temperature T1, the BMS communicates to the entire vehicle to start thermal management, and the water pump 2 in the entire vehicle starts, so that the coolant inside the cooling assembly 400 circulates to cool the battery cell. When the battery temperature drops to a temperature t that reaches below the set temperature T2, the BMS communicates to the entire vehicle to turn off thermal management, and the circuit assembly 500 controls the coolant inside the cooling assembly 400 to not circulate. During the circulation of the coolant, the BMS continuously monitors the feedback signal of the coolant leakage detection device. When the BMS receives a leakage warning signal from the coolant leakage detection device, the circuit assembly 500 communicates the leakage warning signal to the entire vehicle and reports it.

[0122] In some embodiments, the BMS may also continuously monitor the feedback signal of the coolant leakage detection device during the entire driving process of the vehicle so as to be able to determine the coolant leakage caused by the damage of the cooling assembly 400 pipeline. The BMS may monitor the feedback signal of the coolant leakage detection device and the thermal runaway sensor 900 (such as Figure 12 The feedback signal (as shown) is used to determine whether thermal runaway occurs in the power battery 1000 and the cause of the coolant leakage: during thermal runaway, the third liquid cooling element 430 is damaged by the high-temperature airflow of the battery cell, resulting in coolant leakage; or the pipeline of the cooling assembly 400 is deformed, the connection fails, the sealing fails, and other factors lead to coolant leakage.

[0123] In some embodiments, the set temperature T1 is greater than the set temperature T2 to ensure that the battery cell is always within the optimal operating temperature range. Considering that the optimal operating temperature range of the battery cell is below 40°C, in some embodiments, the set temperature T1 is 25°C and the set temperature T2 is 23°C.

[0124] An embodiment of the fourth aspect of the present application provides a vehicle, including a vehicle body and the power battery 1000 described in any embodiment of the second aspect above. The power battery 1000 is installed on the vehicle body 2000. The power battery 1000 can be integrated into the chassis of the vehicle body 2000, or installed under the floor 2100.

[0125] See also Figure 11 In certain embodiments, the two side beams 111 of the power battery 1000 extending in the X-direction are each connected to the sill beam 2200 via mounting bolts. The mounting portion 114 of the side beam 111 extends below and connects to the sill beam 2200. The vertical portion 113 is located inside the sill beam 2200, and a gap is formed between the vertical portion 113 and the inner side of the sill beam 2200 to provide deformation space for the sill beam 2200. Mounting bolts are also provided on the second crossbeam 130 of the power battery 1000, which is connected to the floor 2100 of the vehicle body 2000 via mounting bolts.

[0126] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0127] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise" and "counterclockwise" indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0128] It should be noted that all directional indications in the embodiments of the present application are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0129] In this application, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0130] In addition, the terms "first," "second," and so on, used in this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0131] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification.

[0132] In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the fact that ordinary technicians in this field can implement them. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0133] Although the embodiments of the present application have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and intent of the present application, and that the scope of the present application is defined by the claims and their equivalents.

Claims

1. A power battery, characterized in that: include: A frame structure includes a frame for connecting the vehicle and a first crossbeam disposed within the frame, wherein the inner cavity of the frame is divided into a control compartment and a battery compartment by the first crossbeam; the battery compartment is divided into a plurality of battery subcompartments; the frame structure further includes at least one second crossbeam and at least one longitudinal beam, wherein the second crossbeam and the longitudinal beam are both located within the battery compartment to divide the battery compartment into four or more battery subcompartments; an upper cover connected to the frame structure and covering an upper opening of the inner cavity of the frame; A battery cell assembly is provided in the battery compartment of the frame structure, the battery cell assembly includes a plurality of battery cells distributed in a matrix, a plurality of the battery cells are grouped and loaded into the battery sub-compartment to form a plurality of battery cell units; the battery cell units of the battery cell assembly are arranged one by one in the corresponding battery sub-compartment; A circuit assembly is provided in the control cabin of the frame structure and is electrically connected to the battery core assembly; as well as, A cooling assembly, used to cool the battery cell assembly, comprising: a first liquid cooling element, configured to be disposed on a first side surface of the battery cell assembly, the first liquid cooling element being connected to the frame structure and covering a lower opening of the inner cavity of the frame; a second liquid cooling member, configured to be disposed between adjacent battery cells of the battery cell assembly, the second liquid cooling member being in communication with the first liquid cooling member, and the plane on which the second liquid cooling member is located being arranged at an angle to the plane on which the first liquid cooling member is located; the second liquid cooling member comprising a plurality of second liquid cooling plates and a first distribution pipe for connecting the plurality of second liquid cooling plates, the second liquid cooling plates being located in the middle of the battery cell unit, and extending axially along the longitudinal beam of the frame structure; In which, the second liquid cooling plate includes a liquid cooling plate body and a connecting portion provided at the end of the liquid cooling plate body; the size of the connecting portion is smaller than the liquid cooling plate body, so that the liquid cooling plate bodies and the connecting portion of the two second liquid cooling plates adjacent to each other at head and tail form an escape space; the spacing between the liquid cooling plate bodies of the two second liquid cooling plates adjacent to each other at head and tail is not less than the width of the second crossbeam, the second crossbeam passes through the escape space, and the connecting portion is located above the second crossbeam; both ends of the longitudinal beam are provided with a recessed area, and the bottom wall of the recessed area is provided with a through hole for the pipeline to pass through; the first distribution pipe passes through the recessed area, and the pipe section of the first distribution pipe connected to the first liquid cooling component passes through the through hole.

2. The power battery according to claim 1, characterized in that: The first liquid cooling element includes a first liquid cooling plate; the second liquid cooling plate is arranged at an angle to the first liquid cooling plate; The first distribution pipe is connected to both ends of the second liquid cooling plate.

3. The power battery according to claim 2, characterized in that: The connecting portion is provided with a pipe joint, and two adjacent second liquid cooling plates are communicated with each other through a connecting pipe connected to the pipe joint.

4. The power battery according to any one of claims 1 to 3, characterized in that: The cooling assembly further includes a third liquid cooling element for being arranged on the second side surface of the battery core assembly; the first liquid cooling element, the second liquid cooling element and the third liquid cooling element are in communication; the first liquid cooling element and the third liquid cooling element are both arranged at an angle to the second liquid cooling element; The third liquid cooling member includes a plurality of liquid cooling tubes arranged side by side and a second distribution pipe for connecting the plurality of liquid cooling tubes; the second distribution pipe is connected to both ends of the plurality of liquid cooling tubes; The third liquid cooling element is made of aluminum or polymer material; the melting point temperature of the third liquid cooling element is 120°C to 600°C.

5. The power battery according to any one of claims 1 to 3, characterized in that: The battery cell assembly is placed in the battery compartment in a pressurized state; the high-voltage connection line and the low-voltage connection line connecting the battery cell assembly and the circuit assembly are both close to the first crossbeam; The circuit assembly includes an electrically connected control unit and a power distribution device, the power distribution device includes a housing and a copper busbar assembly and one or more temperature sensors mounted on the housing, the copper busbar assembly being electrically connected to the battery core assembly, the temperature sensor being located in an inner cavity of the housing and electrically connected to the control unit, the copper busbar assembly being bent toward one side of the housing so that a portion of the copper busbar assembly is exposed outside the housing and in thermal contact with the first liquid-cooling element; The upper cover is connected to the frame structure by a fastener, and the fastener is provided with an elastic support portion, so that when the battery pack is installed on the vehicle, the support portion is supported and arranged between the upper cover and the floor of the vehicle body, and the support portion contacts the floor; A fire-retardant plate is provided between the upper cover and the battery core assembly; a bottom guard plate is provided below the first liquid cooling component, and the bottom guard plate is connected to the frame structure.

6. The power battery according to claim 5, characterized in that: The second crossbeam is provided with an avoidance groove; The bottom wall of the recessed area is provided with a mounting hole for mounting a sensor.

7. The power battery according to claim 6, characterized in that: The cooling assembly further includes a third liquid cooling element provided above the battery core assembly, wherein the third liquid cooling element corresponds to the explosion-proof valve port of the battery core; The power battery further includes a coolant leakage detection device electrically connected to the circuit assembly, wherein the coolant leakage detection device is provided at the lowest point of the battery compartment; The power battery further includes a temperature detection device electrically connected to the circuit assembly, wherein the temperature detection device is installed in the mounting hole and is used to detect the temperature of the coolant in the cooling assembly.

8. A fast charging thermal management control method for a power battery according to claim 7, characterized in that: The steps include: The circuit component obtains the temperature t of the battery cell in the battery cell component; When the temperature t reaches a set temperature T1 or higher, the circuit component controls the coolant inside the cooling component to circulate; when the temperature t reaches a set temperature T2 or lower, the circuit component controls the coolant inside the cooling component to not circulate; When the circuit component obtains the leakage warning signal of the coolant leakage detection device, the circuit component communicates the leakage warning signal to the entire vehicle and reports it.

9. A vehicle, characterized in that: The vehicle comprises a vehicle body and the power battery according to any one of claims 1 to 7, wherein the power battery is mounted on the vehicle body.

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