Power battery device formed by multi-layer combination of battery modules

Abstract

The present invention discloses a power battery device formed by multi-layer combination of battery modules, including battery modules in a battery box and a combination form monitoring mechanism; a combined battery support part is arranged on the inner wall of the battery box, and the battery modules located in the upper layer are stacked and arranged side by side relative to the battery modules in the lower layer through the support of the combined battery support part, and are combined into a multi-layer battery module sub-assembly unit fixed relative to the battery box; the upper and lower battery modules are electrically connected through a vertical copper row; the combination form monitoring mechanism includes an elastic pressure monitoring part facing the vertical copper row; by monitoring the change in the pressure value of the elastic deformation of the elastic pressure monitoring part following the inclination or deformation of the vertical copper row, the alignment state between the stacked upper and lower battery modules is monitored. The present invention assembles battery modules in a multi-layer combination manner, realizes the high-capacity design of power batteries, monitors the posture of the stacked combination of battery modules, and improves the stability and safety of power batteries under the high-capacity structure formed by multi-layer combination.

Description

Technical Field

[0001] The present invention belongs to the technical field of power batteries, and particularly relates to a power battery device formed by multi-layer combination of battery modules. Background Art

[0002] A power battery is a battery that provides driving power for an electric vehicle, such as an old man's four-wheel vehicle, a golf course buggy, etc. In order to improve the endurance of such electric vehicles, high-capacity power batteries are the first choice. Most power batteries are assembled from multiple battery modules. In addition to the chemical safety of the battery modules themselves, the stability of their physical assembly is also very important for battery safety. If the combination and assembly of the battery modules are not stable enough, the loose battery modules will rub against each other due to vibration when driving the vehicle. If the long-term wear is not detected in time, it will cause a risk of battery explosion, and the safety needs to be further improved. Summary of the Invention

[0003] Object of the Invention: In order to overcome the deficiencies in the prior art, the present invention provides a power battery device formed by multi-layer combination of battery modules. While increasing the power battery capacity through the stable stacked combination of battery modules, a combined form monitoring mechanism is used to continuously monitor the stacked alignment state of the battery modules, improving the stability and safety of the power battery in a high-capacity structure formed by multi-layer combination.

[0004] Technical Solution: To achieve the above object, the power battery device formed by multi-layer combination of battery modules of the present invention includes battery modules assembled in a battery box and a combined form monitoring mechanism for monitoring the stacked alignment state of the battery modules;

[0005] The battery box has a bottom battery support portion protruding from the inner bottom of the box. The inner wall of the battery box is provided with a combined battery support portion. The battery modules located at the inner bottom of the battery box are supported by the bottom battery support portion and arranged side by side in combination. The battery modules located in the upper layer are stacked and arranged side by side relative to the battery modules in the lower layer through the support of the combined battery support portion, forming a multi-layer battery module sub-assembly unit fixed relative to the battery box;

[0006] The upper and lower battery modules are electrically connected by a vertical copper bar. The combined form monitoring mechanism is correspondingly located on the side of the vertical copper bar. The combined form monitoring mechanism includes an elastic pressure monitoring portion facing the vertical copper bar, and the elastic pressure monitoring portion elastically abuts against the vertical copper bar horizontally. By monitoring the change in the pressure value of the elastic deformation of the elastic pressure monitoring portion following the inclination or deformation of the vertical copper bar, the alignment state between the upper and lower battery modules in the stacked combination is monitored.

[0007] Further, the vertical copper bar is a flexible copper bar. When the upper and lower stacked battery modules are misaligned, the flexible copper bar is driven to incline or deform.

[0008] Further, the battery modules in the vertical columns electrically connected by flexible copper bars are connected to the electrical system of the power battery through rigid copper bars, and the flexible copper bars and the rigid copper bars are respectively located on both sides of the battery module sub-assembly unit.

[0009] Further, the combined form monitoring mechanism includes a mounting seat, and the elastic pressure monitoring part is mounted on the inner wall of the battery box through the mounting seat; the elastic pressure monitoring part consists of a telescopic rod and a pressure sensor spring that provides elastic force to the telescopic rod, and the elastic pressure monitoring parts are linearly arrayed along the vertical extension direction of the vertical copper bar.

[0010] Further, a freely rolling ball is embedded in the telescopic end of the telescopic rod pointing to the vertical copper bar, and the telescopic rod is pressed against the vertical copper bar by rolling of the ball.

[0011] Further, a hollow support steel corresponding to the mounting position of the combined battery support part is provided on the inner wall of the battery box; the combined battery support part is a channel steel frame structure, which includes a connecting part exposed outside the stacking gaps of the upper and lower battery modules and a hidden support part inside. The connecting part is connected to the hollow support steel, and the support part supports the battery modules so that the battery modules are stacked and assembled inside the battery box.

[0012] Further, the battery module includes an outer enclosure and battery cells. A plurality of the battery cells are closely arranged linearly by restricting the degrees of freedom of movement through the outer enclosure; in the same battery module, the linearly arranged battery cells are electrically connected in series and parallel through aluminum bars, and exhaust holes are provided on the aluminum bars to avoid forming air cavities during welding.

[0013] Further, the outer enclosure includes side plates, end plates, pressing strips and bottom flanges; the side plates are located on the length sides of the battery module, the end plates are located on the width sides of the battery module, and the side plates and the end plates cooperate to enclose the linearly arranged battery cells to restrict the horizontal degrees of freedom of the battery cells; the pressing strips are located on the top of the battery module, the bottom flanges are located on the bottom of the battery module, and the pressing strips and the bottom flanges cooperate to clamp the linearly arranged battery cells to restrict the vertical degrees of freedom of the battery cells.

[0014] Further, epoxy boards for insulation protection are provided between adjacent battery modules and between adjacent battery cells.

[0015] Further, the battery box is composed of a box body and a box cover. The box cover is pressed against the sealing gasket to cover the box opening of the box body, so that the battery box is in a sealed state, and the sealed battery box has a one-way pressure relief valve for automatically opening and relieving pressure when the pressure inside the box increases.

[0016] Beneficial effects: While increasing the capacity of the power battery through the stable stacked combination of the battery modules, the present invention uses the combined form monitoring mechanism to continuously monitor the stacked alignment state of the battery modules, improving the stability and safety of the power battery in a high-capacity structure composed of multiple layers; the upper battery module is supported by the combined battery support part, avoiding direct contact installation with the battery box, reducing the direct contact area between the battery module and the inner wall of the battery box, and avoiding the risk of collision between the small vibration displacement of the battery module within the allowable error range and the battery box, further enhancing its stability and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG Figure 1 is a schematic diagram of the overall structure of the power battery device;

[0018] FIG Figure 2 is a schematic diagram of the structure of the battery box;

[0019] FIG Figure 3 is a schematic diagram of the structure of the battery module assembly unit Figure 1 ;

[0020] FIG Figure 4 is a schematic diagram of the structure of the battery module assembly unit Figure 2 ;

[0021] FIG Figure 5 is a schematic diagram of the structure of an embodiment of the combined form monitoring mechanism;

[0022] FIG Figure 6 is a schematic diagram of the structure of the battery module Figure 1 ;

[0023] FIG Figure 7 is a schematic diagram of the structure of the battery module Figure 2 . DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention will be further described below with reference to the accompanying drawings.

[0025] As shown in FIG Figure 1 , FIG Figure 2 and FIG Figure 3As shown in the figure, it includes a battery module 2 assembled in a battery box 1 and a combined form monitoring mechanism 5 for monitoring the stacked alignment state of the battery module 2. The battery box 1 has a bottom battery support portion 3 protruding from the inner bottom of the box, and a combined battery support portion 4 is provided on the inner wall of the battery box 1. The battery modules 2 located at the inner bottom of the battery box 1 are supported by the bottom battery support portion 3 and arranged side by side in combination. The battery modules 2 located in the upper layer are stacked and arranged side by side relative to the battery modules 2 in the lower layer through the support of the combined battery support portion 4, forming a multi-layer battery module partial assembly unit 12 fixed relative to the battery box 1, thereby increasing the overall capacity of the power battery. Moreover, the upper battery modules 2 are supported by the combined battery support portion 4, avoiding direct contact installation with the battery box 1, reducing the direct contact area between the battery modules 2 and the inner wall of the battery box 1, and avoiding the risk of collision between the small vibration displacement of the battery modules 2 within the allowable error range and the battery box 1. Therefore, its stability and safety are further improved.

[0026] As shown in the attached Figure 4 and attached Figure 5 figures, the upper and lower battery modules 2 are electrically connected by a vertical copper row 6, and the combined form monitoring mechanism 5 is correspondingly located on the side of the vertical copper row 6; the combined form monitoring mechanism 5 includes an elastic pressure monitoring portion 51 facing the vertical copper row 6, and the elastic pressure monitoring portion 51 elastically abuts against the vertical copper row 6 horizontally; by monitoring the change in the pressure value of the elastic deformation of the elastic pressure monitoring portion 51 following the inclination or deformation of the vertical copper row 6, the alignment state between the upper and lower battery modules 2 in the stacked combination is monitored. Therefore, while the present invention increases the capacity of the power battery through the stable stacked combination of the battery modules 2, the combined form monitoring mechanism 5 is used to continuously monitor the stacked alignment state of the battery modules 2, improving the stability and safety of the power battery under the high-capacity structure composed of multi-layer combinations.

[0027] As shown in the attached Figure 3 , attached Figure 4 and attached Figure 5As shown, the vertical copper bar 6 is a flexible copper bar. When the upper and lower stacked battery modules 2 are misaligned, the flexible copper bar is driven to tilt or deform. The battery modules 2 in the vertical column electrically connected by the flexible copper bar are connected to the electrical system 17 of the power battery through the rigid copper bar 7. The flexible copper bar and the rigid copper bar 7 are respectively located on both sides of the battery module assembly unit 12. Among them, the rigid copper bar 7 is a solid rigid copper with relatively fixed dimensions. The flexible copper bar is composed of multiple layers of thin copper sheets stacked together, aiming to digest some installation errors. Directly monitoring the misalignment of the battery module 2 is difficult due to the small misalignment amount and low accuracy. Therefore, the combined form monitoring mechanism 5 of the present invention cleverly utilizes the characteristic that the flexible copper bar can be driven to tilt or deform when the battery module 2 is misaligned. By monitoring whether the flexible copper bar is excessively tilted or deformed, it can be indirectly judged that the upper and lower battery modules 2 connected by the flexible copper bar are misaligned. The misalignment monitoring is more intuitive and the accuracy is also higher.

[0028] More specifically, as shown in the appendix Figure 5 As shown, the combined form monitoring mechanism 5 includes a mounting base 50. The elastic pressure monitoring part 51 is mounted on the inner wall of the battery box 1 through the mounting base 50. The elastic pressure monitoring part 51 consists of a telescopic rod 51.1 and a pressure sensor spring 51.2 that provides elastic force to the telescopic rod 51.1. The elastic pressure monitoring parts 51 are linearly arrayed along the vertical extension direction of the vertical copper bar 6 to improve the monitoring coverage. When the flexible copper bar has a slight tilt or deformation, by comparing the pressure monitoring values of the pressure sensor springs 51.2 of each elastic pressure monitoring part 51, when they are inconsistent, it can be judged that the battery module 2 has a stacked combination misalignment, improving the accuracy.

[0029] It should be noted that the elastic pressure monitoring part 51 of the present invention adopts the structural combination of the telescopic rod 51.1 and the pressure sensor spring 51.2. Whether the flexible copper bar tilts or deforms close to or away from the combined form monitoring mechanism 5, the elastic pressure monitoring part 51 can rely on elastic expansion and contraction to abut against the flexible copper bar, and the monitoring accuracy is relatively high.

[0030] In order to reduce the frictional damage of the telescopic rod 51.1 to the vertical copper bar 6, a freely rolling ball 51.3 is embedded in the telescopic end of the telescopic rod 51.1 pointing to the vertical copper bar 6, and the telescopic rod 51.1 abuts against the vertical copper bar 6 by rolling through the ball 51.3.

[0031] As shown in the appendix Figure 1 and in the appendix Figure 2As shown, a frame connection part 1.3 is provided at the installation position of the battery box 1 corresponding to the frame, and the frame connection part 1.3 is arranged in a structure form that avoids the vehicle body. A hollow support steel 9 corresponding to the installation of the combined battery support part 4 is provided on the inner wall of the battery box 1; the combined battery support part 4 is a channel steel frame structure, which includes a connection part exposed in the stacking gap between the upper and lower battery modules 2 and a hidden support part inside. The connection part is connected to the hollow support steel 9, and the support part supports the battery module 2, so that the battery modules 2 are stacked and assembled inside the battery box 1, ensuring that the support for the battery modules 2 is stable enough.

[0032] As shown in the attached Figure 6 and the attached Figure 7 As shown, the battery module 2 includes an outer enclosure and battery cells 20. A number of the battery cells 20 are arranged linearly in close contact with each other by restricting the degree of freedom of movement through the outer enclosure; in the same battery module 2, the linearly arranged battery cells 20 are connected in series and parallel by aluminum bars 2.6, and exhaust holes 60 are provided on the aluminum bars 2.6 to avoid forming air cavities during welding. The electrodes and the aluminum bars 2.6 are laser welded, and air cavities will be formed during the welding process, which will affect the welding strength. By exhausting gas through the exhaust holes 60 in a timely manner, this kind of influence can be effectively avoided.

[0033] The outer enclosure includes side plates 2.1, end plates 2.2, pressing strips 2.3 and bottom flanges 2.5; the side plates 2.1 are located on the length sides of the battery module 2, the end plates 2.2 are located on the width sides of the battery module 2, and the side plates 2.1 and the end plates 2.2 cooperate to enclose the linearly arranged battery cells 20 to restrict the degree of freedom of the battery cells 20 in the horizontal direction; the pressing strips 2.3 are located on the top of the battery module 2, and the bottom flanges 2.5 are located on the bottom of the battery module 2. The pressing strips 2.3 and the bottom flanges 2.5 cooperate to clamp the linearly arranged battery cells 20 to restrict the degree of freedom of the battery cells 20 in the vertical direction. Double-hole insulators 2.4 are installed on the end plates 2.2, and the vertical copper bars 6 and the aluminum bars 2.6 close to the vertical copper bars 6 are both connected to the double-hole insulators 2.4. The bottom flanges 2.5 are formed by inverting the bottom edges of the side plates 2.1. Insulation layers and flame-retardant layers are provided between the side plates 2.1, the end plates 2.2 and the bottom flanges 2.5 and the battery cells 20 respectively, and the pressing strips 2.3 are pressed on the battery cells 20, and both ends of the pressing strips 2.3 are connected to the two end plates 2.2 respectively.

[0034] As shown in the attached Figure 3 As shown, epoxy boards 10 for insulation protection are provided between adjacent battery modules 2 and between adjacent battery cells 20, which are insulating and puncture-proof.

[0035] As shown in the attached Figure 1As shown, the battery box 1 is composed of a box body 1.1 and a box cover 1.2. The box cover 1.2 is crimped with a sealing gasket to cover the box opening of the box body 1.1, making the battery box 1 in a sealed state. And the sealed battery box 1 is provided with a one-way pressure relief valve 8 for automatically opening and relieving pressure when the pressure inside the box rises, such as in the case of internal fire.

[0036] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A power battery device formed by multi-layer combination of battery modules, characterized in that: It includes a battery module (2) assembled in a battery box (1) and a combined form monitoring mechanism (5) for monitoring the stacked alignment state of the battery module (2). The battery box (1) has a bottom battery support part (3) protruding from the inner bottom of the box. A combined battery support part (4) is provided on the inner wall of the battery box (1). The battery modules (2) located at the inner bottom of the battery box (1) are supported by the bottom battery support part (3) and arranged side by side in combination. The battery modules (2) located in the upper layer are stacked side by side relative to the battery modules (2) in the lower layer through the support of the combined battery support part (4), forming a multi-layer battery module sub-assembly unit (12) fixed relative to the battery box (1). The battery modules (2) in the upper and lower layers are electrically connected through a vertical copper bar (6). The combined form monitoring mechanism (5) is correspondingly located on the side of the vertical copper bar (6). The combined form monitoring mechanism (5) includes an elastic pressure monitoring part (51) facing the vertical copper bar (6), and the elastic pressure monitoring part (51) elastically abuts against the vertical copper bar (6) horizontally. By the change in the pressure value of the elastic deformation of the elastic pressure monitoring part (51) following the inclination or deformation of the vertical copper bar (6), the alignment state between the battery modules (2) in the stacked upper and lower layers is monitored. The combined form monitoring mechanism (5) includes a mounting base (50), and the elastic pressure monitoring part (51) is mounted on the inner wall of the battery box (1) through the mounting base (50). The elastic pressure monitoring part (51) is composed of a telescopic rod (51.1) and a pressure sensor spring (51.2) that provides elastic force to the telescopic rod (51.1), and the elastic pressure monitoring parts (51) are linearly arrayed along the vertical extension direction of the vertical copper bar (6).

2. The power battery device formed by multi-layer combination of the battery modules according to claim 1, wherein: The vertical copper bar (6) is a flexible copper bar. When the battery modules (2) in the upper and lower stacked combinations are misaligned, it drives the flexible copper bar to incline or deform.

3. The power battery device formed by multi-layer combination of the battery modules according to claim 2, characterized in that: The battery modules (2) in the vertical columns electrically connected through the flexible copper bar are connected to the electrical system (17) of the power battery through a rigid copper bar (7). The flexible copper bar and the rigid copper bar (7) are respectively located on both sides of the battery module sub-assembly unit (12).

4. The power battery device formed by multi-layer combination of the battery modules according to claim 1, characterized in that: A freely rolling ball (51.3) is embedded in the telescopic end of the telescopic rod (51.1) pointing to the vertical copper bar (6), and the telescopic rod (51.1) rolls and abuts against the vertical copper bar (6) through the ball (51.3).

5. The power battery device formed by multi-layer combination of the battery modules according to claim 1, wherein: The inner wall of the battery box (1) is provided with a hollow support steel (9) corresponding to the installation of the combined battery support part (4). The combined battery support part (4) is a channel steel frame structure, which includes a connecting part exposed to the stacking gap between the battery modules (2) in the upper and lower layers and a hidden support part inside. The connecting part is connected to the hollow support steel (9), and the support part supports the battery module (2) so that the battery module (2) is stacked and assembled inside the battery box (1).

6. The power battery device formed by multi-layer combination of the battery modules according to claim 5, wherein: The battery module (2) includes an outer enclosure and battery cells (20). A plurality of the battery cells (20) are arranged in a linear array in close contact with each other by restricting their degrees of freedom of movement through the outer enclosure; in the same battery module (2), the linearly arranged battery cells (20) are electrically connected in series and parallel through aluminum bars (2.6), and exhaust holes (60) are provided on the aluminum bars (2.6) to prevent the formation of air cavities during welding.

7. The power battery device formed by multi-layer combination of the battery modules according to claim 6, characterized in that: The outer enclosure includes side plates (2.1), end plates (2.2), pressing strips (2.3) and bottom flanges (2.5); the side plates (2.1) are located on the length sides of the battery module (2), the end plates (2.2) are located on the width sides of the battery module (2), and the side plates (2.1) and the end plates (2.2) cooperate to enclose the linearly arranged battery cells (20) to restrict the degrees of freedom of the battery cells (20) in the horizontal direction; the pressing strips (2.3) are located on the top of the battery module (2), the bottom flanges (2.5) are located on the bottom of the battery module (2), and the pressing strips (2.3) and the bottom flanges (2.5) cooperate to clamp the linearly arranged battery cells (20) to restrict the degrees of freedom of the battery cells (20) in the vertical direction.

8. The power battery device formed by multi-layer combination of the battery modules according to claim 7, characterized in that: Epoxy boards (10) for insulation protection are provided between adjacent battery modules (2) and between adjacent battery cells (20).

9. The power battery device formed by multi-layer combination of the battery modules according to any one of claims 1 to 8, characterized in that: The battery box (1) is composed of a box body (1.1) and a box cover (1.2). The box cover (1.2) presses a sealing gasket to cover the box opening of the box body (1.1) to make the battery box (1) in a sealed state, and the sealed battery box (1) is provided with a one-way pressure relief valve (8) for automatically opening and relieving pressure when the pressure inside the box increases.

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