Battery system

Abstract

The embodiment of the application provides a battery system, and relates to the technical field of batteries.The battery system comprises a battery die-cast lower shell, a high-voltage plug-in component, an explosion-proof valve and a smoke sensor are installed on the battery die-cast lower shell; the battery die-cast lower shell is in a frame type structure, a battery module and a main control high-voltage integrated module are installed in the battery die-cast lower shell; a wire harness connects the smoke sensor and the main control high-voltage integrated module; an upper shell liquid cooling integrated plate is assembled on an upper sealing mounting surface of the battery die-cast lower shell; a plurality of series copper bars comprise a plurality of module series copper bars, a positive electrode series copper bar, a negative electrode series copper bar and a plurality of main insurance series copper bars, the module series copper bars are connected with the battery module, the positive electrode series copper bar is connected with a positive electrode of the battery system, the negative electrode series copper bar is connected with a negative electrode of the battery system, and the main insurance series copper bars are connected with a main insurance module of the battery system. The battery system provided by the embodiment of the application can improve the safety of the battery system.

Description

TECHNICAL FIELD

[0001] Embodiments of the present application relate to the technical field of battery, in particular to a battery system. BACKGROUND

[0002] With the popularity of electric vehicles, the requirements for electric vehicles in various aspects are also increasing, and reducing cost and improving safety performance are two major trends in the development of current electric vehicles.

[0003] In the related art, the shell of the battery system includes a frame and a bottom plate, the frame is welded together by four aluminum profile pieces through end face butt joint, and the bottom plate is welded together by four aluminum profile pieces through end face butt joint.

[0004] In the above related art, the overall rigidity of the shell of the battery system is poor, which leads to poor safety of the overall battery system. SUMMARY

[0005] Embodiments of the present application provide a battery system, which can improve the safety of the battery system. The technical solution is as follows:

[0006] According to an aspect of an embodiment of the present application, a battery system is provided, which comprises:

[0007] a battery die-casting lower shell, an upper shell liquid cooling integrated plate, at least one battery module, at least one explosion-proof valve, a high-voltage plug-in, a main control high-voltage integrated module, a plurality of series copper bars, at least one smoke sensor, a bottom guard plate and a wire harness; wherein,

[0008] The high-voltage plug-in, the at least one explosion-proof valve and the at least one smoke sensor are mounted on the battery die-casting lower shell;

[0009] The battery die-casting lower shell is of a frame structure, and a high-voltage integrated warehouse and a plurality of module warehouses are arranged in the battery die-casting lower shell, the main control high-voltage integrated module is mounted in the high-voltage integrated warehouse, and the battery module is mounted in the module warehouse;

[0010] The wire harness connects the smoke sensor and the main control high-voltage integrated module;

[0011] The upper shell liquid cooling integrated plate is assembled on the upper sealing mounting surface of the battery die-casting lower shell;

[0012] The plurality of series copper bars include a plurality of module series copper bars, a positive electrode series copper bar, a negative electrode series copper bar and a plurality of main insurance series copper bars, the module series copper bars are connected with the battery module, the positive electrode series copper bar is connected with the positive electrode of the battery system, the negative electrode series copper bar is connected with the negative electrode of the battery system, and the main insurance series copper bar is connected with the main insurance module of the battery system;

[0013] The bottom protection plate is assembled on the lower sealing mounting surface of the battery die-cast lower shell.

[0014] In some embodiments, the battery die-cast lower shell is integrally die-cast, and the battery die-cast lower shell has the upper sealing mounting surface and the lower sealing mounting surface formed by double-sided shell drawing.

[0015] In some embodiments, the battery die-cast lower shell has a plurality of crossbeams and a plurality of longitudinal beams, and the mounting lifting lugs of the battery die-cast lower shell are arranged at the intersections of the crossbeams and the longitudinal beams.

[0016] In some embodiments, the crossbeams are drawn from the upper surface, and the inside of the crossbeams is provided with at least one transverse reinforcing rib and a plurality of longitudinal reinforcing ribs, and the transverse reinforcing ribs and the longitudinal reinforcing ribs are orthogonal and cross.

[0017] In some embodiments, the inside wall of the battery die-cast lower shell is provided with a mounting boss for mounting and limiting the battery module installed in the frame.

[0018] In some embodiments, the outside of the battery die-cast lower shell is provided with at least one mounting lifting lug for connection with the whole vehicle.

[0019] The bottom surface of the mounting lifting lug is drawn.

[0020] In some embodiments, the mounting lifting lug is provided with a mounting hole, and a plurality of reinforcing ribs extend outward from the mounting hole.

[0021] In some embodiments, the crossbeam on the outside of the battery die-cast lower shell is provided with an explosion-proof valve port, the explosion-proof valve is installed in the explosion-proof valve port, and the explosion-proof valve is internally provided with a burst port.

[0022] In some embodiments, the battery module comprises battery cells, aerogel foam integrated sheets, side plates, end plates, FPCs (Flexible Printed Circuit Boards), insulating fixing seats, partition plates, and insulating plates.

[0023] The aerogel foam integrated sheets are pasted between the battery cells, the insulating plates are pasted at both ends of each row of battery cells, the end plates are mounted on the side opposite to the battery cells of the insulating plates, and the partition plates are pasted between adjacent two rows of battery cells.

[0024] The side plates are pasted on both sides of the battery module, and the side plates are fixedly connected with the end plates.

[0025] The FPCs are mounted on the top of the battery module by pasting.

[0026] The insulating fixed seat is located at the lowermost part of the battery module.

[0027] In some embodiments, the battery module further comprises an explosion-proof valve of the battery cell, the top of the battery cell is provided with a battery cell explosion-proof valve port, and the explosion-proof valve of the battery cell is installed in the battery cell explosion-proof valve port.

[0028] The technical scheme provided by the embodiments of the present application can include the following beneficial effects:

[0029] By using the die-cast lower shell, i.e., the battery die-cast lower shell, in the battery system, the rigidity of the shell in the battery system is improved, the probability of the battery module in the battery die-cast lower shell being extruded is reduced, the risk of explosion of the battery module is reduced, and thus the safety of the battery system is improved.

[0030] It should be understood that the foregoing general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. BRIEF DESCRIPTION OF DRAWINGS

[0031] In order to more clearly illustrate the technical schemes in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0032] Figure 1 is a schematic diagram of a battery system provided by an embodiment of the present application;

[0033] Figure 2 is a schematic diagram of a battery system provided by another embodiment of the present application;

[0034] Figure 3 is a schematic diagram of a battery die-cast aluminum lower shell provided by another embodiment of the present application;

[0035] Figure 4 is a schematic diagram of a lifting point hole provided by an embodiment of the present application;

[0036] Figure 5 is a schematic diagram of a lifting point hole provided by another embodiment of the present application;

[0037] Figure 6 is a schematic diagram of a battery die-cast aluminum lower shell provided by another embodiment of the present application;

[0038] Figure 7 is a schematic diagram of a liquid cooling integrated plate provided by an embodiment of the present application;

[0039] Figure 8This is a schematic diagram of a battery system provided in another embodiment of this application;

[0040] Figure 9 This is a schematic diagram of a battery system provided in another embodiment of this application;

[0041] Figure 10 This is a schematic diagram of the circuit of a battery system provided in one embodiment of this application;

[0042] Figure 11 This is a schematic diagram of a bottom protective plate provided in one embodiment of this application;

[0043] Figure 12 This is a schematic diagram of a bottom protective plate provided in another embodiment of this application.

[0044] Legend:

[0045] 1. Liquid cooling plate insulation foam

[0046] 2. Upper shell liquid-cooled integrated plate

[0047] 3. Battery Module

[0048] 4. Die-cast lower casing of battery

[0049] 5. Bottom Protective Plate

[0050] 6. High-voltage plug-in

[0051] 7. Main control high-voltage integrated module

[0052] 21. Flow channel plate

[0053] 22. Water Inlet

[0054] 23. Water outlet

[0055] 24. Liquid-cooled plate flat plate

[0056] 25. Thermal pad

[0057] 31. Battery Cell

[0058] 32. End plate

[0059] 33. Aerogel foam integrated sheet

[0060] 34. Busbar Group

[0061] 35. Expanding foam

[0062] 36. Gas diversion channel

[0063] 37. Insulating mounting base

[0064] 38. FPC

[0065] 39. Side panels

[0066] 41. rear side beam

[0067] 42. left side beam

[0068] 43. front side beam

[0069] 44. right side beam

[0070] 45. first inner longitudinal beam

[0071] 46. inner cross beam

[0072] 47. second inner longitudinal beam

[0073] 51. bottom guard body

[0074] 52. first lifting point mounting nut

[0075] 53. second lifting point mounting nut DETAILED DESCRIPTION

[0076] The exemplary embodiments will be described in detail herein with reference to the accompanying drawings. In the following description, like reference numerals refer to like elements throughout the description. The following exemplary embodiments are not representative of all embodiments consistent with the present application. Rather, they are merely examples of methods consistent with some aspects of the present application as detailed in the appended claims.

[0077] Reference is made to Figure 1 , which shows a schematic diagram of a battery system provided by an embodiment of the present application. The battery system provided by the embodiment of the present application can include a battery die-cast lower shell 4, an upper shell liquid-cooled integrated plate 2, at least one battery module 3, at least one explosion-proof valve, a high-voltage plug-in 6, a main control high-voltage integrated module 7, a plurality of series copper bars, at least one smoke sensor, a bottom guard 5, and a wire harness. The battery die-cast lower shell is provided with the high-voltage plug-in, the at least one explosion-proof valve, and the at least one smoke sensor. The battery die-cast lower shell is of a frame type structure, and is provided with a high-voltage integrated compartment and a plurality of module compartments. The main control high-voltage integrated module is installed in the high-voltage integrated compartment, and the battery module is installed in the module compartment. The wire harness connects the smoke sensor and the main control high-voltage integrated module. The upper shell liquid-cooled integrated plate is assembled on the upper sealing mounting surface of the battery die-cast lower shell. The plurality of series copper bars include a plurality of module series copper bars, a positive electrode series copper bar, a negative electrode series copper bar, and a plurality of main fuse series copper bars. The module series copper bars are connected with the battery module, the positive electrode series copper bar is connected with the positive electrode of the battery system, the negative electrode series copper bar is connected with the negative electrode of the battery system, and the main fuse series copper bar is connected with the main fuse module of the battery system. The bottom guard is assembled on the lower sealing mounting surface of the battery die-cast lower shell.

[0078] In some embodiments, the assembly of each component of the battery system and the sequence can be: 4 explosion-proof valves and 1 high-voltage plug-in 6 are assembled on the battery die-cast lower shell; 6 battery modules and 1 main control high-voltage integrated module are assembled on the battery die-cast lower shell; the bottom surface of the upper shell liquid cooling integrated plate 2 and the upper sealing surface of the battery die-cast lower shell are automatically glued, and the upper shell liquid cooling integrated plate is assembled on the battery die-cast lower shell. The upper sealing surface of the battery die-cast lower shell is the top surface of the battery die-cast lower shell; the battery system also includes a collection plate, the battery system of the current assembly progress is turned over, 2 smoke sensors are assembled on the battery die-cast lower shell, and a set of communication wire harness is connected to the smoke sensor, the collection plate and the main control high-voltage integrated module; 4 module series copper bars are connected between the battery modules, 2 module series copper bars are connected to the two battery modules at the tail end, the positive series copper bar (also referred to as PACK+ series copper bar) is connected to the positive electrode of the battery system and the main control high-voltage integrated module, the negative series copper bar (PACK- series copper bar) is connected to the negative electrode of the battery system and the main control high-voltage integrated module, and 2 main insurance connection copper bars are connected to the battery module and the main control high-voltage integrated module; the bottom guard plate 5 and the lower sealing surface (i.e. the bottom surface of the battery die-cast lower shell) of the battery die-cast lower shell are automatically glued, and the bottom guard plate 5 is assembled on the die-cast lower shell. At this point, the assembly of the battery system is completed. In some embodiments, as shown in Figure 1 , the battery system also includes a liquid cooling insulation foam cotton 1 covering the liquid cooling integrated plate 2. Wherein, the assembled battery system can refer to Figure 2 .

[0079] In summary, the technical scheme provided by the embodiments of the present application uses a die-cast lower shell in the battery system, i.e. a battery die-cast lower shell, which improves the rigidity of the shell in the battery system, reduces the probability of the battery module in the battery die-cast lower shell being extruded, and reduces the risk of battery module explosion, thereby improving the safety of the battery system.

[0080] In some embodiments, the battery die-cast lower shell is integrally die-cast, and the battery die-cast lower shell has a double-sided shell extraction formed upper sealing mounting surface and a lower sealing mounting surface. In some embodiments, the mounting holes of the battery die-cast lower shell are machined, and the mounting holes located on the same plane can be punched at one time, thereby reducing the processing cost and improving the processing precision.

[0081] In some embodiments, the battery die-cast lower shell has multiple crossbeams and multiple longitudinal beams, and the mounting lifting points of the battery die-cast lower shell are arranged at the intersections of the crossbeams and the longitudinal beams. In some embodiments, the battery die-cast lower shell is a frame as a whole, which is divided into six equal-length and equal-width module compartments by the crossbeams and the longitudinal beams, and there is a high-voltage integrated compartment on the side of the battery die-cast lower shell. The battery modules are assembled in the module compartments, and the master control high-voltage integrated module is installed in the high-voltage integrated compartment. In some embodiments, as shown in Figure 3 the battery die-cast lower shell is formed with upper and lower sealing mounting surfaces by double-sided shell extraction.

[0082] In some embodiments, the upper shell liquid cooling integrated plate has multiple limiting bosses and mounting screw holes on the upper sealing surface of the battery die-cast lower shell, and has a glue-blocking limiting edge at the inner and outer edges. In some embodiments, the intersection of the crossbeams and the longitudinal beams is provided with an intermediate lifting point hole. As shown in Figure 4 , 5 As shown in the drawings, the intermediate lifting point hole is provided with an upper and lower mounting sealing surface and an internal thread, the mounting sealing surface is provided with a sealing ring mounting groove, the crossbeams are provided with an upper shell liquid cooling integrated plate, a mounting surface of a bottom guard plate 5, and a mounting screw hole, and the mounting surface is provided with a sealing ring groove.

[0083] In some embodiments, the crossbeams are extracted from the upper surface, and the inner side of the crossbeams is provided with at least one transverse reinforcing rib and multiple longitudinal reinforcing ribs that are orthogonal and cross.

[0084] In some embodiments, the battery die-cast lower shell frame has one crossbeam and two longitudinal beams on the inner side, the crossbeams are extracted from the upper surface, and the inner side of the crossbeams is provided with one transverse reinforcing rib and multiple longitudinal reinforcing ribs that are orthogonal and cross. In some embodiments, the two side walls of the crossbeams are provided with battery module mounting bosses, the mounting bosses are provided with mounting screw holes, the mounting bosses are hollowed out upward and downward, the inner side of the mounting bosses is provided with reinforcing ribs and is connected with the longitudinal reinforcing ribs on the inner side of the crossbeams.

[0085] In some embodiments, the inner side wall of the battery die-cast lower housing is provided with a mounting boss for mounting and limiting the battery module installed in the frame. In some embodiments, the inner side of the battery die-cast lower housing frame is provided with a module mounting boss, the mounting boss is extracted from the upper shell, the inner side of the mounting boss is provided with a reinforcing rib and is connected with the external frame reinforcing rib; the lower part of the mounting boss is provided with a mounting sealing surface of the bottom guard plate 5, the mounting sealing surface of the bottom guard plate 5 is provided with a mounting limiting boss and a mounting threaded hole; the battery die-cast lower housing frame has two longitudinal beams, the upper surface of the longitudinal beam is extracted, the upper and lower surfaces are provided with a sealing surface and a mounting hole of the upper shell liquid cooling integrated plate, and a mounting sealing surface and a mounting hole of the bottom guard plate 5. In some embodiments, the local position of the lower part of the longitudinal beam is provided with a series copper bar avoidance groove, the inside of the longitudinal beam is provided with a longitudinal reinforcing rib and a plurality of transverse reinforcing ribs, and the longitudinal reinforcing rib is higher than the transverse reinforcing rib. In some embodiments, the front side of the battery die-cast lower housing is provided with a high-voltage integrated warehouse, the high-voltage integrated warehouse is provided with a mounting boss, the inner side of the mounting boss is provided with a reinforcing rib and is connected with the external frame reinforcing rib; the reinforcing rib is provided with a main control high-voltage integrated module mounting threaded hole, the lower part of the mounting boss is provided with a bottom guard plate 5 mounting sealing surface, the bottom guard plate 5 mounting sealing surface is provided with a mounting limiting boss and a mounting threaded hole. In some embodiments, as shown in Figure 6 the battery die-cast lower housing includes a rear beam 41, a left beam 42, a front beam 43, a right beam 44, a first inner longitudinal beam 45, an inner transverse beam 46, and a second inner longitudinal beam 47. The rear beam 41, the left beam 42, the front beam 43, and the right beam 44 form an outer frame of the battery die-cast lower housing, and the first inner longitudinal beam 45, the inner transverse beam 46, and the second inner longitudinal beam 47 divide six module warehouses in the battery die-cast lower housing.

[0086] In some embodiments, a mounting hole is formed in the mounting lug, and a plurality of reinforcing ribs extend outward from the mounting hole. In some embodiments, the outer side of the battery die-cast lower housing is provided with at least one mounting lug for connecting with the whole vehicle; the bottom surface of the mounting lug is extracted. In some embodiments, the outer side of the frame of the battery die-cast lower housing has a mounting lug connected with the whole vehicle. The mounting lug is extracted from the bottom surface, the center of the mounting lug is provided with an upper and lower through mounting hole, and the reinforcing ribs in the mounting lug mainly include seven reinforcing ribs extending outward from the edge of the mounting hole.

[0087] In some embodiments, the upper shell liquid cooling integrated plate is formed by stamping and brazing process. In some embodiments, as shown in Figure 5 and 7As shown, the upper shell liquid cooling integrated plate 2 includes a bottom plate, a flow channel plate 21, a water inlet 22, a water outlet 23, a liquid cooling plate flat plate 24, and a heat-conducting pad 25. In some embodiments, the bottom plate is made of 3-series aluminum alloy material with a thickness of 1.0 mm (millimeter). The bottom plate has corresponding mounting holes at the fixed positions of the battery die-cast lower shell. The heat-conducting pad 25 is pasted at the contact position of the bottom plate and the battery module. In some embodiments, the heat-conducting pad is made of silicone material. In some embodiments, there is a downward flanging at the edge of the bottom plate. In some embodiments, the flow channel plate is made of 3-series aluminum alloy with a thickness of 1.0 mm. The flow channel plate has corresponding mounting holes at the fixed positions of the battery die-cast lower shell. The flow channel plate is provided with a boss at the sealing installation surface of the battery die-cast lower shell to improve the local rigidity. The flow channel plate covers the boss at the position corresponding to the battery module, so as to form a cooling flow channel with the bottom plate. The flow channel is collected at the water inlet and outlet position. In some embodiments, the water inlet and outlet are L-shaped. One end of the water inlet and outlet is welded to the floor, and the other end is connected to the vehicle water pipe.

[0088] In some embodiments, an explosion-proof valve port is formed on the cross beam outside the battery die-cast lower shell. An explosion-proof valve is installed in the explosion-proof valve port. The explosion-proof valve is provided with a burst port inside. In some embodiments, the battery system can be a battery system of an electric vehicle. The battery system can also be referred to as a battery box or a battery pack. In some embodiments, the explosion-proof valve has an outer diameter of 18 mm and is fixed by a hexagonal nut structure. The explosion-proof valve is provided with a burst port inside. One end of the explosion-proof valve is provided with a fixed external thread. The root of the external thread has a sealing ring. The explosion-proof valve is fastened and connected to the battery die-cast lower shell by a nut.

[0089] In some embodiments, as shown in Figure 8 , 9 As shown in ,

[0090] In some embodiments, as shown in Figure 9As shown, the battery module further includes busbars, from plates, busbar groups 34, gas flow grooves 36, and foaming glue 35. The main connection and assembly sequence is as follows: first, 18 battery cells are taken, and each 9 battery cells are arranged in a row, and a total of two rows of battery cells are arranged. The battery cell 31 and the battery cell 31 are pasted with aerogel foam integrated sheet 33, and the two ends of each row of battery cells are pasted with insulating plates. In some embodiments, the insulating plate can be a PC (Polycarbonate, polycarbonate) insulating plate. The two rows of battery cells are separated by a partition plate. Two end plates are taken and placed at the two ends of the two rows of battery cells, and the two rows of battery cells are extruded to the designed length and width of the battery module using an extrusion tool; two side plates are pasted to the two sides of the two rows of battery cells, and the side plates and the end plates are connected using rivets; the insulating plates are pasted to the top of the battery cells, and then the insulating fixing seat is assembled, all the busbars are fixed using a tool, and laser welding is performed, the FPC is pasted to the predetermined position on the top of the battery module, and laser welding is performed; after the battery module is fixed using the tool, the foaming glue is filled on the top of the battery module, so that the assembled battery module is obtained.

[0091] In some embodiments, the battery cell 31 adopts a square shell iron lithium battery cell, the top of the battery cell is provided with positive and negative electrodes, the outer side of the battery cell has an insulating blue film, and the top of the battery cell is provided with a battery cell explosion-proof valve port. In some embodiments, the busbar is punched and formed from 1 series aluminum alloy material; the insulating cover plate is made of PC material with a thickness of 1 mm, and the size of the insulating cover plate is cut according to the length and width dimensions of the top of the module. In some embodiments, the battery cell explosion-proof valve and the pole position of the battery cell 31 have an avoidance hole, and the single-sided plate has an adhesive backing; the aerogel foam integrated sheet is formed by pasting foam on both sides of the aerogel material and then die cutting, the aerogel foam integrated sheet has double-sided adhesive backing, and the thickness of the aerogel foam integrated sheet is calculated to be about 2.5 mm according to the expansion size of the battery cell 31. In some embodiments, the side plate is extruded from 6 series aluminum alloy material, and then machined to be punched and edged, and then bent to be formed. In some embodiments, the inner side of the side plate is insulated and sprayed, the inner side of the side plate is bonded to the battery cell 31, the outer side of the side plate is provided with a lifting lug, the two ends of the lifting lug are bent and turned up to be used for fastening connection with the end plate; the top of the lifting lug is bent and turned up to be used for bonding to the top of the battery cell 31, and the lifting lug has a plurality of mounting holes. The end plate is extruded from 6 series aluminum alloy material, and the main body structure of the end plate is composed of a plurality of cavities and lifting lugs, and then machined to obtain an insulating fixing seat, from plate mounting holes and side plate mounting rivet holes. In some embodiments, the foaming glue is online foaming silica gel, and fills the space on the top of the module.

[0092] In some embodiments, the battery module further includes a battery cell explosion-proof valve, the top of the battery cell is provided with a battery cell explosion-proof valve port, and the battery cell explosion-proof valve is installed in the battery cell explosion-proof valve port. In some embodiments, the position of the battery cell 31 explosion-proof valve forms a directional channel, and a wire harness groove is arranged at the middle position.

[0093] In some embodiments, the high-voltage plug adopts an existing standard two-core high-voltage plug, the fixed direction of the high-voltage plug is from the outside of the battery die-cast lower shell to the inside, the high-voltage plug is fixed on the battery die-cast lower shell through four mounting bolts, the high-voltage plug can be sealed by a sealing ring, the inside of the high-voltage plug is provided with two series copper bars, and the series copper bars are isolated by an insulating piece, and the series copper bars are provided with mounting holes.

[0094] In some embodiments, the master control high-voltage integrated module integrates a relay, a current sensor, a main board, a main fuse, and a communication plug and the like, the master control high-voltage integrated module is externally provided with a fixing hole for the battery die-cast lower shell, the master control high-voltage integrated module is externally provided with a communication interface for connecting a low-voltage wire harness, and the master control high-voltage integrated module is externally provided with a mounting hole connected with the high-voltage plug 6. In some embodiments, the high-voltage loop of the battery system in the embodiment of the application can refer to Figure 10 .

[0095] In some embodiments, the series copper bar adopts T2 red copper material, the series copper bar is externally provided with an insulating thermoplastic sleeve, the connection position is not provided with the thermoplastic sleeve because of the installation, and the mounting surface of the series copper bar is provided with a nickel sheet.

[0096] In some embodiments, as shown in Figure 11 , 12 , the bottom guard plate 5 includes a bottom guard plate body 51, a first lifting point mounting nut 52, and a second lifting point mounting nut 53. In some embodiments, the bottom guard plate 5 adopts a PP (Polypropylene, polypropylene) prepreg + sandwich PP honeycomb plate material, the thickness of the main surface of the bottom guard plate 5 is 10 mm, the thickness of the mounting position is 4 mm, the upper and lower layers of the bottom guard plate 5 are PP prepreg, and the middle part adopts a honeycomb structure; the middle position and the periphery are provided with mounting holes.

[0097] In some embodiments, the communication wire harness assembly includes a communication wire harness between the slave board and the main board, a communication wire harness between the slave boards, and a communication wire harness between the main board and the smoke sensor.

[0098] In the embodiments of the present application, the overall strength is improved through the integrated die-casting frame design and the reinforcing rib design inside all the cross beams and longitudinal beams, thereby improving the extrusion performance of the battery system in the X / Y direction. In some tests, the extrusion performance of the battery system in the X / Y direction can be improved by 2 times, and the impact performance in the Z direction can also be improved. In some tests, the durability of the battery system can be improved by 2 times; the filling design of the bottom guard plate 5 and the glue on the top of the battery module can effectively improve the battery bottom scraping and improve the battery bottom performance by about 50%. In some embodiments, through the main fuse voltage distribution design, the segmented voltage is reduced, and double-layer insulation design is adopted at all electrical connection positions, such as wrapping the copper bar itself with an insulating sleeve, and an insulating film is added at the corresponding position of the die-casting lower shell. In some tests, the busbar of the battery module and the shell of the battery cell 31 are provided with a module blue film, a PC insulating plate and insulating glue, which can improve the insulation performance of the battery module by 50%.

[0099] In the embodiments of the present application, the main logic of battery thermal safety is that when a single battery cell 31 occurs thermal runaway, the heat can be quickly discharged outside the battery pack to reduce the thermal diffusion of the battery cell 31 as much as possible. The specific introduction is as follows: when a single battery cell 31 occurs thermal runaway, the high-temperature gas and particulate matter sprayed by the battery cell 31 can quickly pass through the flue, the battery cell explosion-proof valve and the explosion-proof valve to the outside of the battery system; when a single battery cell 31 occurs severe thermal runaway and produces an open flame inside the battery pack, the bottom guard plate and the corresponding position of the thermal runaway battery cell explosion-proof valve will be melted, thereby forming the shortest channel for the exhaust spray, and the thermal runaway battery cell 31 will pass through the shortest channel to discharge heat to the outside of the battery pack at the fastest speed, thereby reducing the heat accumulation inside the battery pack and reducing the thermal diffusion of the battery cell 31 as much as possible. Since the bottom guard plate 5 is a flame-retardant material, it will not cause a large area of the bottom guard plate 5 to ignite other battery cells 31. Moreover, the spraying direction of the thermal gas of the thermal runaway battery cell is downward (i.e., spraying toward the ground), which will not ignite other components of the vehicle, thereby minimizing the possibility of vehicle combustion.

[0100] In the embodiments of the present application, through the integrated die-casting design of the battery die-casting lower shell, the cost of the battery die-casting lower shell can be reduced by about 30%; the integrated design of the liquid cooling plate and the upper shell can reduce the cost of the upper shell; the integration of the collection plate and the battery module can reduce the cost of the collection wire harness; the control plate and the high-voltage integrated module can reduce the wire harness cost and single piece cost; the universal production of various module accessories can reduce the cost of single accessories and assembly cost. In some tests, except for the battery cell 31, the overall cost of other components can be reduced by 20%; and since the battery module 3 is repairable, the after-sales maintenance cost can be reduced by 50%.

[0101] It should be understood that the "multiple" mentioned herein refers to two or more than two. The "and / or" describes the association relationship of the associated objects, which means that there can be three relationships, for example, A and / or B can represent: A exists alone, A and B exist together, and B exists alone. The character " / " generally represents that the associated objects before and after it are in an "or" relationship.

[0102] The above only describes exemplary embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A battery system, characterized in that, The battery system includes: a die-cast lower battery casing, a liquid-cooled integrated upper casing plate, at least one battery module, at least one explosion-proof valve, a high-voltage connector, a main control high-voltage integrated module, multiple series-connected copper busbars, at least one smoke sensor, a bottom protective plate, and wiring harnesses; wherein... The high-voltage plug, the at least one explosion-proof valve, and the at least one smoke sensor are installed on the die-cast lower housing of the battery. The die-cast lower housing of the battery has a frame structure. The die-cast lower housing of the battery is provided with a high-voltage integration chamber and multiple module chambers. The main control high-voltage integration module is installed in the high-voltage integration chamber, and the battery modules are installed in the module chambers. The wiring harness connects the smoke sensor and the main control high-voltage integrated module; The upper shell liquid-cooled integrated plate is assembled on the upper sealing mounting surface of the die-cast lower shell of the battery; The plurality of series copper busbars include a plurality of module series copper busbars, a positive electrode series copper busbar, a negative electrode series copper busbar, and a plurality of main fuse series copper busbars. The module series copper busbars are connected to the battery modules, the positive electrode series copper busbars are connected to the positive electrode of the battery system, the negative electrode series copper busbars are connected to the negative electrode of the battery system, and the main fuse series copper busbars are connected to the main fuse module of the battery system. The bottom protective plate is fitted onto the lower sealing mounting surface of the die-cast lower housing of the battery.

2. The battery system according to claim 1, characterized in that, The die-cast lower housing of the battery is integrally die-cast, and the die-cast lower housing of the battery has an upper sealing mounting surface and a lower sealing mounting surface formed by double-sided shelling.

3. The battery system according to claim 1, characterized in that, The die-cast lower housing of the battery has multiple crossbeams and multiple longitudinal beams, and the mounting points of the die-cast lower housing of the battery are located at the junction of the crossbeams and the longitudinal beams.

4. The battery system according to claim 3, characterized in that, The crossbeam is shelled from the top surface, and the inner side of the crossbeam is provided with at least one transverse reinforcing rib and multiple longitudinal reinforcing ribs, with the transverse reinforcing ribs and the longitudinal reinforcing ribs intersecting orthogonally.

5. The battery system according to claim 3, characterized in that, The inner wall of the die-cast lower housing of the battery is provided with a mounting boss, which is used to limit the installation of the battery module installed in the frame.

6. The battery system according to claim 1, characterized in that, At least one mounting lug is provided on the outer side of the die-cast lower housing of the battery, and the mounting lug is used to connect to the vehicle. The bottom surface of the mounting lugs is extracted.

7. The battery system according to claim 6, characterized in that, The mounting lug has a mounting hole, and there are multiple reinforcing ribs extending outward from the mounting hole inside the mounting lug.

8. The battery system according to claim 1, characterized in that, An explosion-proof valve port is provided on the crossbeam on the outside of the die-cast lower housing of the battery. The explosion-proof valve is installed inside the explosion-proof valve port and has a rupture port inside.

9. The battery system according to claim 1, characterized in that, The battery module includes a battery cell, an aerogel foam integrated sheet, a side plate, an end plate, a flexible printed circuit board (FPC), an insulating mounting base, a separator, and an insulating board; wherein... The aerogel foam integrated sheet is pasted between the battery cells, the insulating plate is pasted at both ends of each row of battery cells, the end plate is installed on the side of the insulating plate opposite to the battery cell, and the partition is pasted between two adjacent rows of battery cells; The side plates are attached to both sides of the battery module, and the side plates are fixedly connected to the end plates; The FPC is mounted on top of the battery module by adhesive bonding. The insulating mounting base is located at the bottom of the battery module.

10. The battery system according to claim 9, characterized in that, The battery module also includes a cell explosion-proof valve, and the cell explosion-proof valve is installed inside the cell explosion-proof valve port on the top of the cell.

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